Recovery of Pure PVC From Pharmaceutical Composite Packaging via Dissolution-Based Recycling

Pharmaceutical blister packaging, composed of complex multilayer materials such as polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), and aluminum, poses significant recycling challenges due to its intricate structure. This study investigates the feasibility of a dissolution-based recycling process to recover high-purity PVC from pharmaceutical composite packaging. Using specific solvents, PVC was selectively dissolved, enabling the separation of undissolved PVDC and aluminum layers. The process was successfully scaled from laboratory to small-technical scale, achieving a recovery yield of 47% for recycled PVC (rPVC). Comprehensive material characterization, including FTIR and gel permeation chromatography, confirmed the chemical integrity of the recovered PVC, with minimal residual solvent content and no significant degradation. Recycled PVC was incorporated into pharmaceutical film recipes at a 30 phr content, demonstrating comparable mechanical and thermal properties to virgin PVC films. Thermoforming trials further validated the suitability of rPVC-containing films for blister production, with reliable sealing and leak-proof performance. While slight yellowing was observed in rPVC films, this effect is deemed manageable through coloring or enhanced cleaning processes. The study highlights the potential of dissolution-based recycling as a sustainable solution for pharmaceutical blister packaging, offering a pathway to circular use of PVC in the industry. Future work will focus on scaling the process to pilot plant operations and evaluating its economic and environmental viability.