Alu-Alu reverse printing foil: how it works and when to use it
Printing on the cold form side of an Alu-Alu blister: how reverse printing works, artwork tips and when it makes sense.
Business Land Trading,
Most Alu-Alu blisters have a printed lidding foil and a plain silver base. Reverse printing foil changes that: the cold form foil itself carries your brand, so the pack looks finished from both sides.
What "reverse printing" means
Alu Alu cold form foil is a laminate of OPA (oriented nylon), aluminium and PVC. In reverse printing, the design is printed by rotogravure on the inner face of the clear OPA film, in mirror image, before it is laminated to the aluminium. After lamination the ink sits between the OPA and the aluminium, and you see it through the OPA on the outside of the blister.
| Plain Alu Alu foil | Reverse printed Alu Alu foil | |
|---|---|---|
| Look of the cavity side | Plain silver | Your logo, colours or pattern |
| Where the ink sits | No print | Sealed between OPA and aluminium |
| Rub and scratch resistance | Not applicable | Protected by the OPA film |
| Contact with the product | None | None (the product only touches PVC) |
| Barrier | Very high | Very high (aluminium layer unchanged) |
Why brands choose it
- The cavity side is often what patients and pharmacists see first.
- A logo, colour band or repeat pattern makes the pack easier to recognise and harder to copy.
- The print cannot rub off in transport, cartoning or handling.
- Moisture, oxygen and light barrier stays the same as plain Alu Alu foil.
Artwork rules for cold forming
Cold forming stretches the foil where the cavities form, so the artwork has to allow for it:
- Place text and logos on the flat areas between cavities, or use a repeat pattern that still looks right when stretched.
- Send the cavity layout, pitch and web width from your blister tooling so the design can be laid out to it.
- Avoid very fine text and thin lines in the forming zone.
- Supply artwork as PDF or AI with colour references. We send a proof for approval before the cylinders are engraved.
Running it on your blister machine
Reverse printed foil forms on the same cold forming tooling as plain Alu Alu foil and seals to the same PTP lidding foil. A repeat pattern can run without registration. A design that must line up with each cavity needs print registration (an eye mark and sensor) on the blister machine, so check that your machine has it.
Is it worth the extra cost?
Reverse printing adds cylinder cost and a printing step, so it pays off most for high-volume brands, export packs and products that are often counterfeited. For short runs, printed lidding foil on a plain Alu Alu base is the economical choice.
Send your blister layout and artwork on WhatsApp and we will advise on the design and quote for the foil.
Frequently asked questions
Is the ink in contact with the tablet?
No. The ink is between the outer OPA film and the aluminium. The product only touches the PVC layer on the inside of the blister.
What is the minimum order for reverse printed Alu Alu foil?
It depends on the number of colours and the cylinder size. Share your monthly usage on WhatsApp and we will advise.
Topics
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