Blister packaging is the predominant format for oral solid-dose pharmaceutical products, valued for its protection and compliance benefits; however, its complex construction utilising multiple materials (PVC, PVDC, aluminium) renders most blister waste non-recyclable and harmful to the environment. A review of existing literature demonstrated detailed analyses of material properties and laboratory-scale separation techniques, but revealed four critical gaps: (1) a lack of site-level data on actual blister waste volumes and disposal methods; (2) limited evaluation of recycling technologies under real-world, GMP-compliant conditions; (3) insufficient insight into how regulatory frameworks (e.g., the EU Green Deal) translate into operational practice; and (4) minimal incorporation of packaging experts’ perspectives on barriers and enablers for sustainable change.

To address these gaps, this study employed a mixed-method design, conducting an online survey of 30 subject-matter experts across 17 global blister-production sites. Quantitative questions captured annual waste tonnages (90–148,000 kg per site), waste-stream distributions (incineration most prevalent, recycling less common), and material selection drivers (performance rated highest,sustainability ranked lowest). Qualitative responses explored trial outcomes for sustainable alternatives, revealing that 88% of sites had conducted trials but only 11% achieved successful implementation, with performance concerns, lack of suitable alternatives, and high cost cited as primary barriers.

The findings underscore the necessity of strengthening supplier partnerships to enhance alternative material robustness, expanding regulatory engagement to clarify recyclability requirements, and implementing systematic waste-monitoring frameworks to benchmark progress. By using these insights to construct an actionable plan, the pharmaceutical sector can take a crucial first step towards mitigating the environmental impact of blister packaging and fostering long-term sustainability in its global manufacturing network.