Developments in Pharmaceutical Packaging

In my second article about developments in pharmaceutical packaging (see my previous one about the Talking Packaging) I will show solutions for the PIL (Patient Information Leaflet). A PIL often is a dual or multi-layer leaflet, sometimes even in the form of a booklet. They consist of a single- or multi-page leaflet, which, in one way or another, must be incorporated in the pharmaceutical packaging.
They are used for applications where the printable space on the packaging is inadequate for presenting the required information.

For the pharmaceutical industry, the multi-page leaflets have been especially noticeable, as strict regulatory control has increased the need for more product information, often in multiple languages.

It’s not unusual for the published usage instructions and safety information provided with prescription and over-the-counter drugs to get lost, once in the hands of patients. A solution for this problem is offered by Burgopack and Medica Packaging. The packaging of Burgopack encourages compliance by keeping the PIL, blistered product and outer carton permanently connected through a unique sliding mechanism. Medica’s Chrysalis Carton blends the PIL (Patient Information Leaflet) directly into the structure of the carton itself.

As both packages use blisters I added the newest development in blister packaging, namely the paper-free Child-Resistant Blister Lidding Foil of Constantia Flexibles Ltd.
All three are linked to each other, as you will see that they use either the design or the material of each other.

Chrysalis Combines Drug Packet and Patient Leaflet
Medica’s Chrysalis Carton design blends the PIL (Patient Information Leaflet) directly into the structure of the carton itself. Important information about the medication is conveniently connected to the outer carton for the entirety of the products lifecycle.

The Chrysalis Carton was shown in public for the first time at the Pharmapack Europe exhibition held last month in Paris, France.

The Chrysalis Carton from Medica Packaging permanently connects the outer carton and patient information leaflet (PIL) together. The design keeps the leaflet compact and accessible for when the consumer needs access to information about the product. The easy-tear perforation on the back panel of the pack allows the consumer to access information without destroying the whole carton. The large perforated flap to access the leaflet takes up approximately two-thirds of the surface area of the back panel.
With the patient information leaflet already attached to the pack there is no need to insert a separate PIL along with the pack contents.

The company claims, that the design also has the ability to simplify the manufacturing process as the carton is supplied with the leaflet already applied, there is no need to insert it separately. This allows for increased output through faster product inserting, whilst simultaneously decreasing costs.

The fully-patented Chrysalis Carton is brought to market by Burgopak Healthcare & Technology and manufactured under license by Medica Packaging Ltd.

The Burgopak child-resistant slider
The Burgopak child-resistant slider encourages compliance by keeping the PIL, blistered product and outer carton permanently connected through the sliding mechanism. The child-resistant pack’s functionality is based on a pressure point locking system. The blister and PIL are exposed at opposite ends of the pack when the user simultaneously pushes on two tabs and slides the pack open.

For the double-blister pack, the consumer pulls a blister on one side out of the box, which automatically pushes the second blister out the other side. When it is a single-blister pack, the PIL-booklet appears at the other side of the box.
The secret of the packaging, designed by Burgopak, is the sliding band. This band wraps horizontally around the inner panel of the cardboard sleeve. The left side of a paperboard card with a leaflet glued to it is attached to the band. The left side of a blister is then glued to the back of the band. When a blister on the right is extracted, the sliding band pulls to the right and pushes the other blister to the left.

It can be produced in single- and double-blister designs, and even can contain two different products. All designs include PILs which are printed and supplied in a pre-folded booklet format.

The pack is produced on Burgopak’s fully automated machinery and can be supplied to global pharmaceutical and healthcare companies.

The design successfully achieved the U.S. Consumer Product and Safety Commission’s F=1 child resistance and senior friendly effectiveness. This is in conformity with US regulatory standards for poison prevention packaging. This was achieved with impressive results: resistant effectiveness at a pass rate of 98% and senior adult use effectiveness at 95%.

Note: Lisa McTigue Pierce wrote in Packaging Digest a beautiful story about the process of manufacturing and filling the Burgopak sliding blister pack. Worth a read.

Child-Resistant Blister Pack
The Child-Resistant Blister Pack, which was designed for Staxyn, an erectile dysfunction drug from Bayer Pharma, meets both child-resistant and senior-friendly requirements. It has been tested successfully for those two parameters on the American market and will be introduced worldwide in the near future.

This Blister consists of a Coldform Foil and a paper-free Child-Resistant Blister Lidding Foil, Alu15/PET12/Alu15/peelable heat seal lacquer.

Compared with conventional paper/PET/aluminium laminates, the paper-free Child-Resistant Blister Lidding Foil of Constantia Flexibles offers a number of benefits.
For the paper-free make-up of the blister lidding foil the sealing temperature on the blister line is lower than for conventional alu/paper laminates. In turn this means energy consumption is reduced and, as dwell times in the sealing section can be reduced, the blister machine can operate at higher speeds. A further advantage is improved process stability as the bubbles, which could sometimes occur in the paper during sealing, have been completely eliminated.

Furthermore, due to the material composition, using a water-based primer on the decorative outer layer, rather than a primer containing solvents, provides pharmaceutical companies with a sustainable alternative to standard blister lidding foil. The primer also resists the high sealing temperatures generated during the packaging process.

With this new primer a saving of more than 220 tonnes of CO2 emissions in 2011 was possible and according to estimations this figure will increase to more than 640 tonnes per annum in 2012 and beyond.

This Child-Resistant Blister Lidding Foil is available for the opening mechanism peel & push, peel-off or bend & tear.

One response to “Developments in Pharmaceutical Packaging

  1. Hey…very important information …regarding newer devlopment in pharma packaging…sir can u help me in my project’Recent devlopment in pharma packaging’ …wanted some more information..about recent as well as future prospct in pharma package…i m a packaging student..

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