ACG Packaging Materials has launched its breakthrough cold-form blister technology, SuperPod. It enables blister cavities to become dramatically smaller – by up to 39 percent in some cases while maintaining full barrier performance and seamless machine runnability. This cold-form innovation results in a significantly reduced packaging footprint, lower material and resource usage per dosage across the lifecycle and consequently, reduced costs and carbon emissions.

Traditional cold-form aluminium blister cavities are large because those 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.

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.”

The product will be launched at Pharmapack Paris for the European market.

Jochen Scheil, Vice President, Global Sales and Business Development, ACG, 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.”