The pharmaceutical industry relies heavily on plastic components and packaging to produce medications safely, effectively, and efficiently. From pill bottles and medication blister packs to tubing and valves for IV bags, various types of plastic are essential to safely contain, deliver, and administer medications.
Understanding the different categories of pharmaceutical plastics, their properties, and typical applications can provide helpful insight into this vital aspect of the drug manufacturing process. In this guide, we'll explore the most common plastics used in pharmaceuticals and medical devices.
The Big Three: PET, HDPE, PVC
Three of the most ubiquitous plastics used in pharmaceutical manufacturing are polyethylene terephthalate (PET), high-density polyethylene (HDPE), and polyvinyl chloride (PVC). Each offers distinct properties that make them well-suited for specific pharmaceutical applications.
Polyethylene terephthalate (PET)
Known for its clarity, toughness, and barrier properties, PET is commonly used to make prescription bottles and over-the-counter medication containers. Its high mechanical strength allows it to endure filling, capping, shipping, and normal handling without damage. PET also provides an excellent oxygen and carbon dioxide barrier, helping extend drug shelf life.
Additional pharmaceutical uses for PET include clamshell pill packaging, thermoformed trays, and some IV and dialysis components. PET's ability to withstand sterilisation by irradiation also makes it a popular choice for disposable syringes and other devices.
High-density polyethylene (HDPE)
With its low moisture absorption, high tensile strength, and moderate rigidity, HDPE is well-suited to pharmaceutical bottles and caps. Milky in colour, it is often used for opaque containers to protect light-sensitive medications.
HDPE offers similar advantages to PET in terms of chemical resistance, durability, and barrier properties. However, it is cheaper to produce and provides greater impact resistance. You'll find HDPE used for everything from pill bottles and medication cups to caps and closures.
Polyvinyl chloride (PVC)
Thanks to its clarity, chemical resistance, durability, and low cost, PVC is used extensively in intravenous (IV) bags, tubing, and fluid sets. It is also common in medical blister packs and clamshells.
With the addition of plasticisers, PVC becomes softer and more pliable, ideal for flexible containers and tubing that connect IV bags to catheters. PVC provides an effective oxygen barrier to keep IV fluids sterile throughout storage and use.
Specialty Pharmaceutical Plastics
Beyond the big three, other plastics offer unique properties for specialised applications:
Polyethylene (PE)
The low-density form of polyethylene offers flexibility and impact resistance ideal for pharmaceutical bottle caps and closures. It provides a compliant seal to protect against contamination. Low-density PE is also used for films and seals in blister packaging.
Polypropylene (PP)
Similar in properties to PET, polypropylene offers high tensile strength, chemical resistance, and heat resistance. Common pharmaceutical uses include syringes, medication cups, closures, and some IV components.
Polystyrene (PS)
Polystyrene is used to make disposable petri dishes, flasks, and other cell culture plasticware. It can be easily injection moulded into a variety of laboratory tools. Polystyrene offers optical clarity and can withstand repeated sterilisation.
Polycarbonate (PC)
With its extreme impact resistance and optical clarity, polycarbonate is ideal for specialised medical storage and drug delivery devices. These include lockable carts for narcotics, inhalers, and auto-injector pens.
Acrylic (PMMA)
Like polycarbonate, acrylic's optical clarity makes it useful for medical devices like syringes and IV components. It can be injection moulded, extruded, or cast. Acrylic's rigidity allows it to maintain dimensional stability.
ABS
ABS or acrylonitrile butadiene styrene provides strength, rigidity, and chemical resistance. Combined with antistatic properties, it is popular for laboratory equipment like petri dishes, vials, funnels, and other devices.
PTFE (Teflon®)
With its nonstick surface, high heat resistance, and chemical inertness, PTFE is essential for pharmaceutical processing equipment and components exposed to aggressive chemicals. Common applications include gaskets, seals, tubing, and valve components.
Key properties and considerations
Selecting the right pharmaceutical plastic requires evaluating key material properties and performance criteria:
- Chemical resistance - Ability to withstand exposure to drugs, solvents, and cleaning agents.
- Thermal stability - Maintains integrity through heating/cooling during processing and sterilisation.
- Clarity/opacity - Clear or opaque as needed for the application and drug being contained.
- Durability - Withstands routine handling, shipping, and administration throughout the entire product lifecycle.
- Sterilizability - Compatible with sterilisation methods like irradiation, steam, or ethylene oxide.
- Biocompatibility - Non-toxic, non-allergenic, non-reactive for safe contact with pharmaceuticals and fluids.
Cost, manufacturability, and sustainability are also key considerations. By thoroughly evaluating these factors, pharmaceutical companies can select the optimal plastic components, containers, and packaging for each drug.
The importance of expertise
With stringent regulatory standards in the pharmaceutical industry, choosing the right plastics is critical. Partnering with an expert manufacturer provides access to the latest medical-grade materials and innovative solutions.
For over years, SDI Plastics has been providing high-quality plastics manufacturing services to the pharmaceutical sector across Australia. Their ISO-certified facilities allow them to produce plastic components, packaging, and assemblies to the industry's exacting quality and compliance standards.
SDI Plastics' in-house experts collaborate directly with pharmaceutical companies through every phase of the project, from initial design and material selection through prototyping, testing, and production. Their full-service capabilities and wealth of experience with medical plastics helps clients successfully develop everything from pharmaceutical packaging and delivery systems to analytics equipment and labware.
By leveraging SDI Plastics' extensive capabilities, pharmaceutical companies can bring to market products much faster whilst meeting product quality, efficacy, and safety imperatives. Learn more about partnering with Australia's leading plastics manufacturer for your next pharmaceutical project!
