Smaller blister cavities without sacrificing barrier performance
ACG Packaging Materials has launched SuperPod™, a cold-form blister technology aimed at improving sustainability and production efficiency. The concept is straightforward: SuperPod™ allows much smaller blister cavities—up to 39% smaller in some cases—while preserving full barrier performance and maintaining smooth, reliable machine runnability.
This cold-form innovation delivers a much smaller packaging footprint by using fewer materials and fewer resources per dose throughout the product lifecycle. The downstream impact is straightforward: lower costs and lower carbon emissions.
Traditional cold-form aluminium blister cavities are large because they cannot be drawn deeply without the risk of aluminium rupture. Larger cavities increase the size of primary, secondary, and tertiary packaging, leading to higher material consumption, warehouse space requirements, and logistics costs.
The core innovation behind SuperPod™ lies in a superior multi-layer laminate engineered for exceptional cold-drawing capability, enabling deep-draw cavity formation while retaining the full protective properties of cold-form aluminium. A well-designed format also increases the number of blisters per shot—by up to three times in some cases—freeing up production capacity and reducing manufacturing costs.
Performance on high speed packaging lines
SuperPod™ ensures smooth and reliable performance on existing high-speed packaging lines. In addition, it is available with both PVC-based and halogen-free sealing layers. Together, these benefits make SuperPod™ a compelling solution for manufacturers seeking to improve both operational efficiency and environmental impact.
Dr Akbar Ali, General Manager and Head of Development and Technology, ACG Packaging Materials, commented “We’re excited to debut SuperPod™ at Pharmapack 2026. The technology effectively makes cold-form blisters lighter by reducing material usage per dosage. We see significant opportunities, particularly for high-count formats such as 20-count vitamins and B-complex capsules, where traditional cold-form blisters become impractically large. It also performs exceptionally well for moisture-sensitive and oncology products, where reduced headspace and narrower cavity spacing help minimise gas and moisture exposure, offering enhanced protection. SuperPod™ has already undergone testing with major pharmaceutical manufacturers on high-speed blister lines, demonstrating performance comparable to standard cold-form materials, but with far greater forming capability.”
Jochen Scheil, Vice President, Global Sales and Business Development, added “The launch of SuperPod™ encourages the industry to rethink decades-old design conventions and embrace smaller, smarter, and more sustainable blister formats. Digital tools such as QR codes and electronic leaflets further support this transition by reducing reliance on large blister surface areas for printed information.”
SuperPod at Pharmapack Paris
SuperPod: technology to make cold-form blisters lighter by reducing material usage per dosage. (photo: ACG)
SuperPodTM will be launched at Pharmapack Paris for the European market on stand 4H12 (Hall 4). ACG will also be displaying from its range of sustainable materials and barrier protection products including:
RecycloPodTM: recycle ready mono material;
DryPodTM: desiccant based active cold form laminates;
AlumLid EcoTM: sustainable lidding foil suitable for online printing and high-speed machine;
Sustainable cold form: PVC, and halogen free symmetrical cold form material;
CR SF lidding foil: creating an industry benchmark;
UltrasafeTM: thermoforming materials with high level barrier protection;
SupposeTM: wide range of thermoform and cold form suppository material for all types of forming machines.
