Cold Form Blister Packaging Market Size, Share & COVID-19 Impact Analysis, By Material (Aluminum, Oriented-polyamide, Polyvinyl Chloride (PVC), Polyethylene (PE), Polypropylene (PP), and Polyethylene Terephthalate (PET)), By Application (Pharmaceuticals, Electronics and Semiconductors, Foods, Consumer Goods, and Others), and Regional Forecast, 2025-2032

The global cold form blister packaging market size was valued at USD 4.65 billion in 2024. The market growth is projected to be USD 4.88 billion by 2025 to USD 6.64 billion by 2032, exhibiting a CAGR of 4.51% during the forecast period. Asia Pacific dominated the cold form blister packaging market with a market share of 41.07% in 2024. Moreover, the cold form blister packaging market in the U.S. is projected to grow significantly, reaching an estimated value of USD 1.32 billion by 2032, driven by the rising demand of form blister in pharmaceutical industry.

Cold form blister packaging, also known as cold form aluminum blister packaging solution uses thin sheets of laminate film containing aluminum. To create blister packs with cold form, a stamp is used to force the sheets into a form, stretching the aluminum-based film that retains and takes the mold shape after removal of the stamp.

Cold form blister packs can be made using a variety of forming and lidding materials, such as polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), oriented-polyamide, and aluminum-based foil. Growing demand for blisters from the pharmaceutical industry is driving the market growth. This packaging format is majorly used for packaging solid unit pharmaceutical doses. Hence, the market is highly influenced by the latest trends and developments in the pharmaceutical packaging market.

GLOBAL COLD FORM BLISTER PACKAGING MARKET OVERVIEW

Market Size & Forecast:

• 2024 Market Size: USD 4.65 billion
• 2025 Market Size: USD 4.88 billion
• 2032 Forecast Market Size: USD 6.64 billion
• CAGR: 4.51% from 2025–2032

Market Share:

• Asia Pacific dominated the market in 2024 with a 41.07% share, rising from USD 1.81 billion in 2023 to USD 1.91 billion in 2024.
• By material, aluminum led the market due to its superior barrier properties against moisture, light, and oxygen.
• By application, pharmaceuticals remained the top segment, expected to hold a 41.51% market share in 2024, driven by the growing demand for tamper-evident, moisture-protective packaging.
• Cold form blister made solely from aluminum is emerging as a sustainable alternative, minimizing plastic usage and enhancing recyclability.

Key Country Highlights:

• United States: Projected to reach USD 1.32 billion by 2032, fueled by strong pharmaceutical industry growth and demand for secure drug packaging.
• China & India: Rapid R&D expansion and increasing drug consumption support strong regional growth.
• Germany & France: Strict European regulations for recyclable materials boost cold form adoption.
• Brazil: Growth driven by increased drug development and healthcare investment.
• Middle East & Africa: Moderate growth due to expanding presence of multinational pharmaceutical companies and healthcare infrastructure development.

COVID-19 IMPACT

Rapid Growth in the Pharmaceutical Industries Boosted the Market Growth During COVID-19 Pandemic

The COVID-19 outbreak had a multifaceted effect on the market growth globally. The pandemic led to a surge in demand for pharmaceuticals, including medications and vaccines, which in turn increased the demand for cold form blister packs. However, cold form blister packaging industry also suffered from a shortage of raw material components and packaging materials due to supply chain disruptions that affected production and delivery timelines for a short period. Innovation and rapid development of COVID-19 vaccines helped the industry to recover from this short setback. Packaging manufacturers prioritized the production of pharmaceutical packaging to meet the increased demand for rapid distribution of essential pharmaceutical products globally. These factors helped the market in reporting overall growth during the pandemic.

Cold Form Blister Packaging Market Trends

Adoption of Cold Form Blisters Made from Aluminum Only is set to Emerge as a Key Trend

Cold form blister packs are generally known as cold form aluminum blister packs since they are primarily made of aluminum. The base layer of this packaging solution is made from aluminum, and the lid or cover layer is of different materials such as PVC, PE, PP, and others. Plastic is known to be a polluting material and has a lot of scrutiny around its usage. Packaging manufacturers have developed an innovative and technological solution for blister packs made only from aluminum. This technique avoids the usage of plastic and proves to be a clear example of the circular economy. This new packaging not only meets the hygiene and safety criteria required by the pharmaceutical industry but is completely recyclable and, therefore, designed to set new sustainability standards. The usage of mono-materials such as aluminum as raw material will also make raw material sourcing and production procedure of blisters less complex. These factors will contribute to the cold form blister packaging market growth over the forthcoming years. Asia Pacific witnessed a cold form blister packaging market growth from USD 1.81 billion in 2023 to USD 1.91 billion in 2024.

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Cold Form Blister Packaging Market Growth Factors

Growing Demand for Blisters from the Pharmaceutical Industry is Enhancing the Market Growth

The rapid rise in demand for blisters and the increasing research and development activities in pharmaceutical & biotech firms are driving the growth of the market. According to a report published by the International Federation of Pharmaceutical Manufacturers & Associations, in 2020, 53 new medicines were launched, while currently, more than 9,000 compounds are at different stages of development globally. The pharmaceutical industry has seen consistent growth over the years due to the aging population, increased healthcare awareness, and the demand for various medications. Blister packs are very commonly used for packaging solid unit pharmaceutical dosage forms such as capsules, tablets, and others. Cold form blister packaging is tamper-evident, and any attempt to tamper with the packaging is easily detectable. The pharmaceutical industry highly appreciates this feature as it is one of the major industries affected by counterfeiting. Such unique characteristics of cold form blisters are boosting the market growth.

Superior Physical Properties to the Alternative Packaging Formats to Boost Market Growth

Blister packaging is made from different types of materials, such as aluminum, oriented-polyamide, PVC, PE, PP, polyethylene terephthalate (PET), and others. Generally, the cost of cold form blister packs tends to be higher than thermoform blister packs. However, thermoform blister packaging is not suitable for light-sensitive drugs due to the clear PVC material. Cold form blister packaging uses aluminum as a base layer and, in many cases, as lidding material. The usage of aluminum prevents light or UV radiation and increases the shelf life of perishables. Different lidding materials can be used to meet the product needs, such as hard aluminum can be used for push-through applications. Soft aluminum can be used for child safety, and paper aluminum can be used for peel-off applications. 

The packaging industry has also increased its investments and is opting for cold form blisters for packaging products other than just pharmaceuticals, such as consumer goods, food condiments, and electronics. Thus, such factors are responsible for propelling the market growth.

RESTRAINING FACTORS

High Cost of Aluminum Compared to PVC Hampers the Market Growth Worldwide

Although, cold form blisters offer significant benefits, the high cost of raw materials, especially aluminum, is anticipated to impede the market growth. The growth of the market is hindered due to the imposed regulations for certain packaging materials usage, such as plastic. The high costs related to the cold form blister are a major factor hampering the cold form blister packaging market growth. In addition, the lack of modern and advanced infrastructure in many emerging and underdeveloped countries and the trained personnel shortage also hinder market expansion.

Cold Form Blister Packaging Market Segmentation Analysis

By Material Analysis

Aluminum Segment Dominates the Market Due to the Material’s Substantial Advantages

By material, the market is classified into aluminum, oriented-polyamide, polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), and polyethylene terephthalate (PET).

The aluminum segment holds the largest share of the cold form blister packaging market globally and is anticipated to grow during the projected period. The rapid increase in plastic usage for cold form blister packaging is accredited to its fundamental properties, including the provision of a barrier against moisture, light, and air. Aluminum provides increased protection of highly sensitive drugs from the factors such as moisture, light, and fluctuating temperature that can lead to loss of stability, shortened shelf life of the products, or ineffective drug delivery. It is a bit expensive but improves the safety of cold form blister products, propelling the segment's growth.

The PVC segment holds the second-largest market share due to it being easy to form and seal, low in price, and can provide sufficient support for glass packaging such as ampoules, vials, and syringes and is expected to grow steadily during the forecast period.

By Application Analysis

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Pharmaceuticals Segment Dominates the Market Due to the Rising Need for Form Blisters in this Sector

Based on the application, the market is segmented into pharmaceuticals, electronics and semiconductors, foods, consumer goods, and others.

The pharmaceuticals segment is dominating the cold form blister packaging industry globally. A steady increase in cold form blisters is seen for pharmaceuticals, as a very high percentage of pharmaceutical products available in the market are sensitive and require optimal moisture protection. Typically packed products in aluminum blisters include tablets, high-value, and highly potent drugs. Films of materials, such as PVC, PP, and oriented polyamide, offer transparency for the less sensitive drugs and bridge the gap between the cost-effectiveness of low-cost thermoform blisters and high-cost aluminum (alu-alu) cold form blisters, which are highly appreciated by the pharmaceutical industry, thus driving the segment growth. The pharmaceuticals segment is expected to hold a 41.51% share in 2024.

REGIONAL INSIGHTS

The market is studied across North America, Europe, Asia Pacific, Latin America, and the Middle East and Africa.

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Asia Pacific holds the largest global cold form blister packaging market share. The growing food, healthcare, and pharmaceutical industries in Asia Pacific are driving the market growth. Increased investment in the R&D sector and the population growth in developing countries, such as China, Japan, and India, are propelling the region's growth.

North America is the second dominating region in the market. The growing pharmaceutical industry, leading consumer products industry, and the presence of key market players drive the market growth in the North American region.

Europe, after North America, is also one of the dominating regions and is estimated to attain massive growth over the estimated time frame. The rules and regulations from the European medicines agencies, especially for the materials utilized in cold form blister packs, promote the use of recyclable packaging materials, contributing to market growth in Europe. Moreover, the growing research and development activities is also anticipated to propel the European cold form blister packaging market.

Latin America will witness significant growth during the forecast period owing to the increasing drug development activities by the leading drug manufacturing companies.

The Middle East & Africa cold form blister packaging market is anticipated to grow moderately during the forecast period owing to the rising expansion activities of established producers in the region.

List of Key Cold Form Blister Packaging Market Companies

Rising Key Players Focus on Customer Base Expansions to Boost Market Growth

The global cold form blister packaging market is fragmented and competitive. Regarding market share, the few major players are dominating the market by offering innovative packaging in the packaging industry. These major players in the market are constantly focusing on their customer base expansion and innovation globally.

Major players in the market include Constantia Flexibles, Amcor, Bilcare Limited, Honeywell International Inc., and others. Numerous other players operating in the industry are focused on delivering advanced packaging solutions.

List of Key Companies Profiled:

• Constantia Flexibles (Austria)
• Amcor (Switzerland)
• Bilcare Limited (India)
• Honeywell International Inc. (U.S.)
• TekniPlex (U.S.)
• UFlex Limited (India)
• Liveo Research AG (Switzerland)
• Aphena Pharma Solutions (U.S.)
• R-Pharm Germany GmbH (Germany)
• Wasdell Group (U.K.)
• Pack Time Innovations Pvt. Ltd. (India)
• HySum Europe GmbH (Germany)
• Perlen Packaging AG (Switzerland)
• Ecobliss Pharmaceutical Packaging (Netherlands)
• Svam Toyal Packaging Industries Pvt. Ltd. (India)

KEY INDUSTRY DEVELOPMENTS:

• July 2023 – Constantia Flexibles launched its latest pharmaceutical packaging solution, the cold form foil REGULA CIRC. The packaging replaces traditional PVC with a polyethylene (PE) sealing layer, reducing plastic content while increasing the proportion of aluminum. REGULA CIRC embraces the principles of the circular economy through increased aluminum percentage.
• June 2023 – TekniPlex Healthcare has extended its North American footprint and global capacity with a new 200,000-square-foot manufacturing plant in Madison, Wisconsin, U.S. This facility is estimated to boost the company’s lamination capacity for a broad range of materials, including PET, nylon, paper, foil, PE, EAA, and ionomer, in both peelable and non-peelable structures.
• July 2021 – The Wasdell Group, a leading outsourcing partner to the pharmaceutical industry, announced its acquisition of Planned Packaging Limited & Planned Packaging Films Limited (PPF), which is a specialist packaging supplier to the medical device and pharmaceutical sectors. The acquisition will strengthen and expand Wasdell’s capability to be a fully integrated supplier to its growing client base within the life science and medical device sector.
• August 2020 – Perlen Packaging built a new film coating plant at its operating site in Brazil, where it co-financed a new calendaring facility for mono film production to develop its activities in Latin America further.
• August 2020 – Switzerland-based Liveo Research Group, a leading manufacturer of high-performance barrier films used for blister packaging in the pharmaceutical industry, announced a twenty-thousand-ton capacity expansion to its existing coating capabilities in Boetzingen, Germany. With this investment, Liveo is set to fortify its market position in high-barrier products.

REPORT COVERAGE

The report provides detailed market analysis and focuses on key aspects such as key players, competitive landscape, product/service types, market segmentation, Porter's five forces analysis, and leading applications of the product. Besides, the report offers insights into the market trends and highlights key industry developments. In addition to the above factors, the report encompasses several factors that contributed to the market's growth in recent years.

Report Scope & Segmentation