PP-Based Blends with PVP-I Additive: Mechanical, Thermal, and Barrier Properties for Packaging of Iodophor Pharmaceutical Formulations

The influence of minor components on leaching molecular iodine (I₂) through polypropylene (PP)-based packaging from a povidone iodine-based (PVP-I) formulation, simulating an ophthalmic application, was evaluated. I₂ is a cheap, broad-spectrum, and multi-target antiseptic. Nevertheless, it is volatile, and the prolonged storage of I₂-based formulations is demanding in plastic packaging because of transmission through the material. Therefore, we explored the possibility of moderating the loss of I₂ from an iodophor formulation by introducing small amounts of molecular iodine into the polymer material commonly used in eyedropper caps, i.e., PP. Thus, PP was blended via an extrusion process with a polymeric complex containing iodine (such as PVP-I) or with a second polymeric component able to complex the I₂ released from an iodophor solution. The aim of this work was to introduce I₂ into PP-based polymer matrices without using organic solvents and indirectly, i.e., through the addition of components that could generate molecular iodine or complex it in the solid phase, as I₂ is heat-sensitive. To increase the miscibility between PP and PVP-I, poly(N-vinylpyrrolidone) (PVP) or a vinyl pyrrolidone vinyl acetate copolymer 55/45 (Sokalan) were added as compatibilizers. The PP-based binary and ternary blends, in granular or sheet form, were characterized thermally (Differential Scanning Calorimetry, DSC, and Thermogravimetric analysis, TGA), mechanically (tensile tests), morphologically (scanning electron microscopy (SEM)), and chemically (attenuated total reflectance Fourier transform infrared (ATR-FTIR)). Additionally, the variation in wettability induced by the introduction of the hydrophilic minority components was determined by static contact angle measurements (static contact angle (SCA)), and tests were carried out to determine the barrier properties against oxygen (oxygen transmission rate (OTR)) and molecular iodine. The I₂ leaching of the different blends was compared with that of PP by monitoring the I₂ retention in a buffered PVP-I solution via UV-vis spectroscopy. Overall, the experimental data showed the capability of the minority components in the blends to increase thermal stability as well as act as a barrier to oxygen. Additionally, the PP blend with PVP-I induced a reduction in molecular iodine leaching in comparison with PP.