Aptar brings Activ-Film to dry powder inhalers

Aptar Active Material Science has commercialised its Activ-Film technology for the first time in a capsule-based dry powder inhalation system, extending its active packaging platform into a demanding pharmaceutical application where moisture control can directly influence drug stability and performance.

The technology is integrated into the blister packaging used to protect individual dry-powder capsules, creating a controlled microenvironment around the drug throughout its shelf life.

Active material controls the blister microclimate

For the new application, a customised piece of Activ-Film is sealed inside an aluminium blister cavity and connected to the area containing the pharmaceutical capsule through a channel.

This configuration allows the active material to manage conditions within the drug cavity without coming into direct contact with the capsule itself. The system can be engineered according to the specific moisture, oxygen or impurity-control requirements of an individual pharmaceutical formulation.

Moisture can affect dry powder performance

Dry powder inhalation products can be particularly sensitive to humidity. Changes in moisture levels may influence powder properties, chemical stability and the ability of the formulation to aerosolise correctly when the patient uses the inhaler.

Packaging therefore plays an important role beyond simple containment. Maintaining a stable microclimate can help minimise degradation risks and support consistent therapeutic performance throughout storage and use.

Technology builds on Activ-Polymer platform

Activ-Film is based on Aptar’s 3-Phase Activ-Polymer technology, a material science platform that can be adapted to manage moisture, oxygen, volatile compounds and other environmental factors within packaging.

The technology has previously been used in applications including oral solid-dose medicines, diagnostic products, implants and medical devices. Its commercial use in a capsule-based DPI represents an expansion into inhaled drug delivery.

Integrated protection can simplify pharmaceutical packaging

Traditional moisture protection can require separate desiccant components or additional packaging layers. Integrating active material directly into the blister structure can provide a more targeted approach by controlling conditions within each individual cavity.

Aptar’s Activ-Blister solutions are designed to protect moisture- and oxygen-sensitive products while reducing packaging complexity and maintaining convenience for patients and pharmaceutical manufacturers.

Drug stability becomes increasingly packaging-dependent

The pharmaceutical sector is developing increasingly complex formulations, including inhaled medicines where small changes in environmental conditions can affect product performance. This is increasing demand for packaging capable of actively managing the environment surrounding the drug rather than relying solely on passive barrier properties.

Active materials can help pharmaceutical developers meet long-term and in-use stability requirements while reducing the risk of potency loss, degradant formation or impurities developing during storage.

Inhalation technologies continue to expand

Dry powder inhalation is also moving beyond established respiratory treatments as developers investigate pulmonary delivery for a wider range of molecules and therapeutic areas. Aptar is separately developing DPI platforms for high-payload formulations and conducting research into inhaled biologics and other therapies.

As these applications become more demanding, packaging technologies capable of controlling the drug microenvironment are likely to become increasingly important. The commercialisation of Activ-Film for capsule-based DPI packaging demonstrates how active material science can be integrated directly into pharmaceutical packs to support stability, product integrity and drug-delivery performance.