ACG Introduces SuperPod for Drug Protection and Sustainability

At Pharampack 2026, ACG Packing is unveiling the SuperPod™, its newest innovation in cold-form blister technology. According to an ACG press release, this new packaging design will drastically reduce cavity size, which reduces the strain on production resources and manufacturing costs (1).

The physical limitations of cold-form aluminum have historically dictated the size and cost of pharmaceutical packaging. Because standard aluminum foils are susceptible to rupture when drawn too deeply, manufacturers have been forced to utilize large cavities that increase the overall packaging footprint (1). These oversized blisters subsequently demand more warehouse space, increase material consumption, and elevate logistics costs throughout the supply chain. The SuperPod is designed to optimize the balance between material performance and operational efficiency (1).

How does enhanced draw capability impact manufacturing efficiency and sustainability?

The technical foundation of this development is a multi-layer laminate designed for superior cold-drawing (1). By allowing for deep-draw cavity formation without compromising the protective barrier of the aluminum, the technology can reduce cavity sizes by up to 39% in specific applications. A well-engineered format can increase the number of blisters produced per shot by as much as three times, effectively freeing up existing manufacturing capacity and lowering per-unit costs (1). These reductions in material and resource usage per dosage contribute to a smaller environmental footprint across the product lifecycle.

Why is this innovation particularly relevant for moisture-sensitive and high-count dosage forms?

The ability to minimize cavity dimensions and spacing has direct implications for drug stability and protection. Dr. Akbar Ali, GM and head of Development and Technology at ACG Packaging Materials, stated in an ACG press release, “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 minimize 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” (1).

Maintaining seamless runnability on high-speed packaging lines is essential for operational stability. This material is designed to work with existing equipment and is available with both polyvinyl chloride (PVC) and halogen-free sealing layers (1). The flexibility to use PVC or more sustainable alternatives allows manufacturers to adapt to evolving environmental requirements, according to ACG. In an ACG press release, Jochen Scheil, VP of 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 Quick Response (QR) codes and electronic leaflets further support this transition by reducing reliance on large blister surface areas for printed information” (1). By utilizing QR codes, manufacturers can maintain information density while further reducing the physical size of the blister card. This technology is part of a broader shift at ACG toward sustainable oral dosage solutions, which includes such products as RecycloPod™, created with recycle-ready mono-materials.

What other innovations is ACG pushing forward?

To address challenges involving moisture protection with highly sensitive molecules, ACG introduced the DryPod™ in 2025 (2). Unlike traditional co-extruded structures, materials used in the DryPod are engineered using a proprietary lamination-based approach. This technical shift allows the laminate to function consistently across all standard blister-forming technologies, eliminating the need for specialized equipment retrofits or costly process modifications (2). This means the material can be integrated into existing blister lines with minimal disruption. Furthermore, the laminate is compatible with any polyethylene-sealable lidding foil, which enhances procurement flexibility and supports supply chain agility across global operations.

References:

1. ACG. ACG Packaging Materials Launches SuperPod™ Setting a New Benchmark for Cold-form Blister Design. Press Release. Jan 21, 2026.
2. ACG. ACG launches DryPod™ – A Breakthrough Desiccant-Based Cold-Form Laminate Delivering Superior Protection for Moisture-Sensitive Pharmaceutical Blisters at PMEC 2025. Press Release. Dec 2, 2025.