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XPP Medical Solutions

Safe, Sustainable & Cost Effective.

From thermoformed medical kits & trays to form-fill-seal unit dosing pods and blister packs, our XPP Medical polypropylene rollstock solutions provide a safe, sustainable and cost effective PS & PVC replacement solution for medical, pharmaceutical and healthcare packaging applications, offering compatibility with existing thermoforming and form-fill-seal systems & process.

Innovations in Sustainable Medical Packaging Solutions

Polystyrene and PVC have historically been the material of choice for a vast range of medical and pharmaceutical packaging applications – from diagnostic kits and sterile barrier trays, to form-fill-seal unit-dosing pods, and much more. But lack of recycling options and sustainability challenges, health and safety concerns regarding presence of certain materials in PS and PVC, and the rising cost of materials, have sent OEM medical companies and converters in search of alternatives.

Previous attempts to develop replacements for PS and PVC in these applications with traditional PP or PET have resulted in solutions that cost more, fall short on performance, cause processing issues or require significant capital expenditure to modify existing equipment – until now.

Enter XPP Medical Solutions – offering a safe, sustainable and cost effective PS & PVC replacement solution. ICPG’s XPP™ polypropylene is a revolutionary mono-material rollstock solution that maintains all of the positive attributes of current PS and PVC materials – processing, function, safety, quality – in the form of a more sustainable and cost effective solution that offers drop-in process compatibility for PS & PVC replacement made easy.

Enhanced Barrier

Inherent improvements to barrier properties without the use of specialty barrier materials or coatings resulting in structure simplification and extended shelf-life potential:
– 90/90% improvement in OTR/MVTR vs traditional PP
– 100/150% improvement in OTR/MVTR vs PS
– Comparable MVTR vs PET/PET-G
– Comparable MVTR vs PVC
– Coextrusion with EVOH for high barrier shelf-stable applications

Drop-in Processing

Enhancements to key functional properties offer process compatibility with existing thermoforming & form-fill-seal equipment & processes:
– Compatible with existing trimming & cutting stations
– Minimal CAPEX for equipment & tooling modifications
– No loss in cycle times or through-put

Improved Performance

High stiffness attributes provide similar characteristics to current PS packaging functionality & processing:
– Maintains PS “snapability” & “scorability” for FFS
– Increased flex modulus/stiffness of 450,000 Psi vs 300,000 Psi for PS
– Controlled shrinkage mitigates downstream processing issues
– Compatibility with laser etching processes

Simplified & Safe

Enhanced properties result in a clean, safe & simplified solution with using no additives, mineral fillers, or specialty coatings providing:
– Compatible with medical sterilization processes including EtO and autoclave
– Compatible with disinfectants including hydrogen peroxide & steam sterilization
– Produced from non-toxic polypropylene materials
– Free from BPAs, Styrene & Ethylbenzene
– Free from chloride and heavy metals
– Compliant with Proposition 65 guidelines

Download the XPP Medical Solutions Product Sheet to learn more today!

Check All the Boxes

Economics or Environment?

With XPP you don’t have to choose. Our mono-material XPP Medical Solutions maintain all of the positive attributes of current materials: processing, function, barrier protection, quality – all the form of a more sustainable, recyclable and cost effective solution vs PS, PVC and PET/PET-G alternatives.

Download the XPP-M Economic Comparison Case Study!


Light-weight PP-based solutions promote improved sustainability profile & a reduced carbon footprint vs heavier materials like PS, PVC & PET/PET-G:
– Less CO2 equivalents by weight
– Less solid waste by weight
– Lower fuel consumption & lower emissions


In comparison to other barrier material structures produced from a complex mix of materials, XPP solutions are produced from polypropylene materials resulting in a more recycle-friendly solution. Comparative barrier materials such as HIPS/PVDC must be identified using the Resin ID Code #7, which limits opportunities for recycling and re-use in other applications.

XPP Polypropylene Solutions are:

– Identifiable as RIC #5 for both enhanced barrier & high barrier
– Structures pre-qualified with How2Recycle
– Non-mineral filled structures maintain PP density & ability to sort for recycling

Resource Efficiency

Light-weight and low-density XPP material solutions offer a 12% density reduction in comparison to PS and a 30% density reduction in comparison to PET. This density reduction results in a higher yield (more parts) during thermoforming processes, reduced cost and reduced material consumption in comparison to PS and PET:

– 1,000,000 lbs PP = 1,120,000 lbs PS
– 1,000,000 lbs PP = 1,310,000 lbs PVC
– 1,000,000 lbs PP = 1,340,000 lbs PET/PET-G

  • Polystryene
  • Polypropylene
  • Polypropylene
  • Food Packaging

Make it Yours

  • Capabilities

    Monolayer Rollstock
    Multilayer Coextruded Rollstock
    Thin-gauge Extrusion Capabilities From .015” – .080’”

  • Customization options

    Custom Opaque Colors
    Custom Bi-colors
    Custom Finish, Incl. Gloss, Smooth, Matte & Haircell
    Clear and Clear-tinted Materials
    Performance Additives
    UV/light Degradation Additives

  • Compatible Process


  • Proven Excellence

    Learn about our longstanding commitment to clean, quality, fully-certified manufacturing processes.

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  • Reliable Resources

    Uncover an expertly crafted collection of technical, material and process know-how in the Innovative Insights Blog.

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  • Superior Support

    Trying something brand new? Tap into our onsite technical support services to help you through the development process – one material at a time.

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  • Custom Solutions

    Explore exactly what your custom materials are capable of. Explore our portfolio of specialty additives and innovative materials.

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