New single-material blister pack sets new standard for sustainable OTC products

Bayer and Liveo Research Introduce New PET Blister Packaging with Reduced Environmental Impact.

Bayer has announced the launch of polyethylene terephthalate (PET) blister packaging for its Aleve brand in the Netherlands, marking a first in the healthcare industry. Developed in collaboration with packaging specialist Liveo Research, the new packaging format replaces traditional polyvinyl chloride (PVC) with PET, significantly lowering the environmental impact of over-the-counter (OTC) blister packaging.

According to Bayer, this shift aims to reduce the packaging’s carbon footprint by 38% per unit and reduce resource use, with a reported 78% decrease in water usage and a 53% reduction in land use compared to previous packaging formats. Additionally, the new design is 18% lighter per unit.

Blister packaging has historically been difficult to recycle due to its multilayer structure of plastic and aluminium. Bayer’s switch to PET represents a step toward sustainability, though the company highlights that wider changes in recycling infrastructure will be essential to fully integrate this new packaging type into a circular economy.

This initiative is part of Bayer’s long-term vision to transition its entire OTC blister packaging portfolio to sustainable materials.

Chris Padain, Vice President and Global Head of Design, Packaging, Product Experience & Sustainability for Bayer’s Consumer Health division, said: With its improved carbon footprint and decreased impact on water use and land, we’re proud of this step forward in our journey towards environmental sustainability.

Bayer is also working with industry groups, including the Global Self-Care Federation and the Blister Pack Collective, to promote systemic changes in packaging and recycling. The company has recently joined The Recycling Partnership, contributing to research and industry collaboration to advance packaging innovations and recycling processes.