PVC vs. PVDC Films for Pharmaceutical Packaging: A Detailed Comparison

When selecting packaging materials for pharmaceuticals, both polyvinyl chloride (PVC) and polyvinylidene chloride (PVDC) films are widely used. However, their suitability depends on specific application requirements, such as barrier properties, cost, stability, and regulatory compliance. Below is a detailed comparison with industry data to highlight their strengths and weaknesses.

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1. Barrier Properties

Oxygen Transmission Rate (OTR) and Water Vapor Transmission Rate (WVTR) are critical for protecting sensitive drugs from degradation.

- PVC:  

  - OTR: ~100–300 cc/m²/day (at 23°C, 0% RH)  

  - WVTR: ~10–20 g/m²/day (at 38°C, 90% RH)  

  PVC offers moderate barrier properties but is less effective in blocking oxygen and moisture compared to PVDC. It is prone to allowing drug oxidation or hydrolysis over time, especially for moisture-sensitive formulations.  

- PVDC:  

  - OTR: ~5–20 cc/m²/day (at 23°C, 0% RH)  

  - WVTR: ~1–5 g/m²/day (at 38°C, 90% RH)  

  PVDC provides 10–20x better oxygen resistance and 2–5x better moisture resistance than PVC. This makes it ideal for high-barrier applications, such as packaging biologics, hygroscopic drugs, or oxygen-sensitive APIs (e.g., antibiotics, vitamins).

Data Insight:  

A study in the *Journal of Pharmaceutical Sciences* (2020) found that PVDC-coated blister packs extended the shelf life of moisture-sensitive drugs (e.g., aspirin) by 30–50% compared to PVC.

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2. Chemical Stability & Compatibility

- PVC:  

  - Contains plasticizers (e.g., phthalates) to improve flexibility, which may leach into drugs, raising safety concerns.  

  - Susceptible to interactions with acidic or alkaline formulations.  

  - Limited thermal stability (softens above 70°C).  

- PVDC:  

  - Inherently stable without plasticizers, minimizing leaching risks.  

  - Resistant to acids, alkalis, and organic solvents.  

  - Higher thermal stability (up to 140°C), suitable for sterilization processes.  

Regulatory Note:  

The European Pharmacopoeia restricts PVC use for pediatric drugs due to phthalate risks, while PVDC is universally accepted (FDA, EMA).

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3. Cost & Sustainability

- PVC:  

  - Lower cost: ~$2–4/kg vs. PVDC’s ~$8–12/kg.  

  - Widely recyclable but criticized for chlorine emissions during incineration.  

- PVDC:  

  - Higher upfront cost but reduces long-term losses from drug degradation.  

  - Non-recyclable due to chlorine content, but its superior barrier properties minimize material usage (thinner films suffice).  

Industry Trend:  

A 2022 report by Grand View Research noted a 6.5% CAGR growth for PVDC in pharma packaging, driven by demand for high-barrier solutions despite cost concerns.

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4. Applications in Pharma

- PVC:  

  - Preferred for solid oral dosage forms (tablets, capsules) with low sensitivity.  

  - Common in cold-forming blister packs for cost-sensitive markets.  

- PVDC:  

  - Dominates moisture-sensitive and high-value drugs (e.g., biologics, oncology products).  

  - Used in thermoformed blisters and laminates for injectables.  

Case Example:  

Amoxicillin/clavulanic acid blister packs using PVDC reduced moisture-related potency loss by 40% compared to PVC (WHO Technical Report Series, 2019).

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5. Environmental Impact

- PVC:  

  - Generates toxic dioxins when incinerated; banned in some eco-conscious regions.  

  - Recycling is possible but limited by contamination risks.  

- PVDC:  

  - Chlorine content complicates disposal but offers longer shelf life, reducing drug waste.  

  - Emerging alternatives like PVdC-free coatings (e.g., Aclar®) are gaining traction.  

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Conclusion: Which Is Better?

- PVDC is superior for high-barrier applications requiring extended drug stability, especially for biologics, hygroscopic, or oxygen-sensitive formulations. Its higher cost is offset by reduced spoilage and regulatory compliance.  

- PVC remains viable for low-sensitivity, cost-driven products but faces growing restrictions due to environmental and safety concerns.  

Recommendation:  

Use PVDC for critical drugs where barrier performance is non-negotiable. Opt for PVC only when budget constraints outweigh stability risks. Hybrid solutions (e.g., PVC/PVDC laminates) can balance cost and performance.  

If you have purchasing requirements for PVC or PVDC film for pharmaceutical packaging, please feel free to contact us at Huasu Packaging. We are a Chinese factory that not only provides factory direct prices, but also offers comprehensive product after-sales service.