APET, RPET, or PVC/APET Laminate: Choosing the Right Rigid Film

Why rigid film selection decides pack performance

Rigid film sits at the centre of every thermoformed pack. It determines how deeply the cavity can be drawn, how clearly the product is seen, how well the lidding seals and how the finished pack behaves in transport. Switching material without checking those four points is one of the most common causes of late-stage line problems.

This guide compares the three rigid films we supply most often: APET, RPET and PVC/APET laminated sheet.

Start from the pack format, not the material

The pack format narrows the material choice faster than any data sheet. Work outwards from what the pack has to do.

Comparing the three materials at a glance

Ranges are indicative and depend on thickness, cavity geometry and machine setup. Confirm with a line trial before commercial ordering.

Clarity and appearance

All three materials are transparent. APET and the APET face of the laminate hold gloss best after deep drawing, which matters for retail-facing packs. RPET is slightly lower in light transmission, so it suits trays and consumer healthcare formats more than high-visibility display packs.

Barrier performance

Moisture barrier is where the materials separate most clearly. PVC offers a moderate moisture barrier, APET a lower one, and adding a PVDC coating or moving to an aluminum structure raises barrier substantially. If the formulation's stability data demands a low WVTR, material selection should follow that data rather than appearance. For a fuller discussion of how barrier figures are measured and compared, see our article on reading barrier data sheets.

Forming behaviour and depth

PVC and the PVC/APET laminate form deepest, which is why they remain the default for deep-draw blisters. APET and RPET form at lower temperatures and suit shallower cavities and trays. If a pack needs both a deep draw and a high-gloss printed surface, the laminate is usually the straightforward route.

Sealing

Sealing follows the material at the seal interface. PVC and PVC/APET laminates are normally sealed on the PVC face with a standard PVC-compatible lacquer. APET and RPET require a lidding lacquer matched to PET. When you change material, expect to re-verify seal strength, seal temperature window and peel behaviour on your own sealing equipment.

Sterilization compatibility

Where steam sterilization is required, the pack structure normally changes rather than the film alone. Discuss the requirement with us before specifying.

Recyclability and recycled content

APET, RPET and PVC/APET laminates are all mono-material options in the sense that they keep a single polymer chemistry per face, which supports recycling streams. RPET goes further by incorporating post-consumer recycled content, declared and verified per batch, which makes it the usual choice when a brand has a stated recycled-content target. Packs that combine PVC with a PVDC coating or with aluminum are harder to separate at end of life.

A practical selection checklist

• Confirm the pack format and required forming depth first.
• Check the formulation's stability data before trading barrier for appearance.
• Decide whether recycled content is a stated requirement.
• Confirm the sterilization method early; it can eliminate options.
• Match the lidding lacquer to the material face you are sealing.
• Run a line trial at production speed before committing to a specification.

Matching material to application

• Deep-draw pharmaceutical blisters and standard blisters: PVC or PVC/APET laminate
• High-clarity supplement and cosmetic packs: APET or PVC/APET laminate
• Medical device and diagnostic trays: APET, RPET
• Recycled-content retail and consumer healthcare formats: RPET
• Moisture-sensitive formulations: PVC/PVDC or aluminum-based structures

Product pages with full specifications: APET Rigid Film, RPET Rigid Film, PVC/APET Laminated Rigid Sheet, Standard Blister PVC, PTP Aluminum Foil.

Next steps

If you are unsure which film suits a specific pack, send us the cavity drawing, the dosage form and the sterilization method. We will come back with a recommended material and a trial plan. Request a quote.