Foil/plastic pouches, blister and strip packaging MCQs With Answer

Introduction: This quiz collection focuses on foil/plastic pouches, blister, and strip packaging — key unit-dose systems in pharmaceutical manufacturing. It is designed for M.Pharm students preparing for exams and industry roles, covering materials (PVC, PVDC, Aclar, aluminium laminates), forming and sealing processes (thermoforming, cold-forming, heat/cold seals), barrier properties (OTR, WVTR), equipment parameters, common defects, testing/validation, and child‑resistance and stability considerations. Questions probe deeper into material selection, lamination strategies, sealing mechanics, and package performance tests to build practical understanding for formulation protection, compliance, and scale-up. Use these MCQs to assess and reinforce applied knowledge in packaging science and technology.

Q1. Which material is most commonly used as the thermoformable base film for standard blister packs?

• Polyethylene terephthalate (PET)
• Polyvinyl chloride (PVC)
• Polyethylene (PE)
• Polytetrafluoroethylene (PTFE)

Correct Answer: Polyvinyl chloride (PVC)

Q2. Which film is known for providing the best moisture barrier for blister packaging among the options below?

• PVC (Polyvinyl chloride)
• PETG (Polyethylene terephthalate glycol)
• Aclar (PCTFE)
• Polypropylene (PP)

Correct Answer: Aclar (PCTFE)

Q3. What is the primary function of lidding foil in a blister pack?

• To provide aesthetic printing surface only
• To act as the thermoformable cavity material
• To create a hermetic seal and act as a barrier to moisture, light and gases
• To reduce the blister forming temperature

Correct Answer: To create a hermetic seal and act as a barrier to moisture, light and gases

Q4. What differentiates a cold-seal lamination from a heat-seal lamination for blister lidding?

• Cold-seal uses UV-curable lacquer while heat-seal uses hot-melt adhesive
• Cold-seal requires no pressure while heat-seal requires high pressure
• Cold-seal uses pressure-sensitive adhesive and requires no heat, suitable for heat-sensitive products
• Cold-seal is only used with aluminium blister bases while heat-seal is for plastic bases

Correct Answer: Cold-seal uses pressure-sensitive adhesive and requires no heat, suitable for heat-sensitive products

Q5. Which material is most commonly used for cold‑form (cold‑forming) blister base foils?

• Transparent PVC film
• Aluminium-based cold-form foil
• Polyethylene film
• Polycarbonate sheet

Correct Answer: Aluminium-based cold-form foil

Q6. Which of the following is a principal advantage of strip packaging for tablets?

• It always provides a clearer window for product visualization than blisters
• It is best suited for liquid dose forms
• Compact unit-dose format with reduced material usage and good tamper evidence
• Requires no heat sealing and is always recyclable

Correct Answer: Compact unit-dose format with reduced material usage and good tamper evidence

Q7. If the heat-seal temperature in a blister sealing operation is set too low, what is the most likely outcome?

• Excessive browning of the film
• Seal over-strength causing difficulty in opening
• Poor sealing strength leading to leaks and loss of barrier
• Immediate melting of the lidding foil

Correct Answer: Poor sealing strength leading to leaks and loss of barrier

Q8. Which analytical parameter specifically quantifies how much oxygen passes through a packaging film?

• Moisture Vapor Transmission Rate (MVTR)
• Tensile Strength
• Oxygen Transmission Rate (OTR)
• Heat Seal Initiation Temperature (HSIT)

Correct Answer: Oxygen Transmission Rate (OTR)

Q9. Why is PVC often laminated with PVDC or replaced by Aclar in blister applications for hygroscopic drugs?

• Because PVC is too rigid and PVDC softens it
• Because PVC has poor moisture barrier (high WVTR) and needs better barrier layers
• Because PVC cannot be thermoformed
• Because PVDC gives better printability only

Correct Answer: Because PVC has poor moisture barrier (high WVTR) and needs better barrier layers

Q10. Why are domed or deep-pocket blister cavities used for certain products like softgel capsules?

• They reduce the surface area for printing
• They provide a protective void to prevent product deformation and allow easy extraction
• They make heat sealing unnecessary
• They improve oxygen transmission to the product

Correct Answer: They provide a protective void to prevent product deformation and allow easy extraction

Q11. Typical thermoforming temperature range for PVC blister forming is approximately:

• 20–50 °C
• 80–100 °C
• 160–180 °C
• 300–350 °C

Correct Answer: 160–180 °C

Q12. What is the role of heat-seal lacquer or sealant coating applied to lidding foils?

• To improve the decorative appearance only
• To increase the thermoformable film thickness
• To provide a reliable heat-sealable layer that bonds to the blister base
• To make the foil electrically conductive

Correct Answer: To provide a reliable heat-sealable layer that bonds to the blister base

Q13. What is a key advantage of cold‑formed (alu‑alu) blister packs compared with thermoformed PVC blisters?

• They are transparent for product visualization
• They have excellent barrier properties to moisture and oxygen
• They form at room temperature without equipment
• They are always cheaper to produce

Correct Answer: They have excellent barrier properties to moisture and oxygen

Q14. Which test is used to quantify the force required to open a sealed blister by peeling the lidding foil?

• Seal integrity leak test
• Peel strength (seal peel) test
• Water vapor permeability test
• Compression testing

Correct Answer: Peel strength (seal peel) test

Q15. Which statement best characterizes Aclar film used in packaging?

• Aclar is a low-cost PVC substitute with poor barrier
• Aclar is a PCTFE film with outstanding moisture barrier but is comparatively expensive
• Aclar is an adhesive lacquer for lidding foils
• Aclar is a paper-based backing for strip packs

Correct Answer: Aclar is a PCTFE film with outstanding moisture barrier but is comparatively expensive

Q16. For highly hygroscopic APIs requiring the best protection, which primary packaging is typically selected?

• Clear PVC thermoformed blister with standard aluminum foil lidding
• Cold-formed aluminium/aluminium (Alu-Alu) blister
• Simple polyethylene pouch without laminate
• Cardboard folding carton without inner lining

Correct Answer: Cold-formed aluminium/aluminium (Alu-Alu) blister

Q17. Which of the following is a primary advantage of blister packaging in patient use?

• Eliminates the need for any secondary packaging
• Provides unit‑dose presentation with tamper evidence and dose control
• Always provides the lowest cost packaging option
• Guarantees indefinite long‑term stability without testing

Correct Answer: Provides unit‑dose presentation with tamper evidence and dose control

Q18. Which defect is most commonly associated with excessive thermoforming temperature or dwell time in blister forming?

• Increased barrier performance
• Browning, film thinning or burn-through of the forming film
• Improved peelability
• Reduced cavity depth

Correct Answer: Browning, film thinning or burn-through of the forming film

Q19. Strip packs for tablets often use which type of lidding material to ensure individual cavities are sealed?

• Non-laminated kraft paper
• Aluminium foil laminate specifically designed for strip-seal
• Uncoated PET film
• Cotton-based sheet material

Correct Answer: Aluminium foil laminate specifically designed for strip-seal

Q20. For moisture-sensitive formulations packaged in blisters, which validation parameter is most critical to ensure product protection?

• Color fastness of printing inks
• Seal integrity and closure performance (leak/peel/pressure tests)
• No‑load machine speed capability
• Thickness of outer carton only

Correct Answer: Seal integrity and closure performance (leak/peel/pressure tests)

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