Objective: To optimize aluminum packaging used for medicinal products based on universal design (UD), the material properties of this packaging were evaluated.  In addition, a questionnaire on the usability of this packaging was conducted for the same purpose.
Methods: Tear resistances of the films used for both aluminum and polypropylene packaging were measured using a tensile tester. To evaluate tear linearity of both packaging types, gap widths from standard line to tear line were measured after the samples were torn 75 mm in length.  A survey of 480 pharmacists was conducted on usability.
Results: Regarding material properties, the maximum value of tear resistance for aluminum packaging was approximately 28 times higher than that for polypropylene packaging.  The maximum gap width from standard line to tear line was approximately 10 mm for both types of packaging.  Regarding the questionnaire, the total response rate was 41.0%.  In valid responses, approximately 90% of pharmacists experienced frustration when opening aluminum packaging and requested improvements in usability. In addition, 88% of pharmacists opened packaging in the longitudinal direction by hands.  For the important point in usability of aluminum packaging, the following answers were confirmed: “speed of opening (43%),” “ease of tearing (31%)” and “ease of taking blisters out (20%).”
Conclusion: Our results suggest that current aluminum packaging is difficult to open and tear linearly based on the evaluation of material properties.  These points are consistent with the concerns highlighted in the survey of pharmacists.  We therefore conclude that the points to be improved when considering UD are the ease of opening and linear tearing for more efficient use of aluminum packaging in a clinical setting.