Pharmaceutical packaging machines: The latest machine solutions meet these trends and challenges
The pharmaceutical industry is in a state of flux. Innovations in drug production and new legal requirements pose challenges for packaging machine manufacturers. Sustainability, digitalisation and personalisation play a key role here. However, current developments show how creatively machine manufacturers are dealing with these trends.
The AF-408 folding machine is designed for leaflets and can be converted in just a few seconds.When chronically ill patients become even sicker despite optimal therapy, the reason is often frighteningly simple: doses are forgotten, medication is reordered too late or treatment is discontinued by the patient for other reasons – often out of sheer forgetfulness. Unfortunately, we humans unlearn faster than we can establish new habits.
“Adherence” and “compliance” are now terms that not only electrify doctors and pharmacists. Especially at a time when digital aids – from smartphones and smartwatches to new “gadgets” – are increasingly characterising our everyday lives.
Smart packaging supports adherence to treatment
Technologies such as RFID and NFC not only allow supply chains to be tracked seamlessly, but also the intake of medication: US start-up AdhereTech, for example, offers intelligent medication bottles that help patients to take their medication correctly and regularly. The bottles are equipped with sensors that monitor whether and when a patient has taken a dose. If a dose is forgotten, the bottle automatically reminds the patient by means of acoustic and visual signals, text messages and phone calls – and doctors and carers can also be informed.
The “smart bottle” is just one example of the importance of digital functions in pharmaceutical packaging. Such solutions have long been particularly important for temperature-sensitive medicines, whose storage and transport must be closely monitored. As a result, more and more materials have to be added to packaging lines and integrated into folding cartons.
In response to these challenges, FACHPACK exhibitor MM Packaging, for example, offers ComboPack, a service in which a secondary packaging material (flyer, wallet, label, information or promotional card, etc.) is glued onto a folding carton. MM Packaging solves another problem with PiggyBack: two or three folded package inserts are glued together on the back to create more space for information without making the pack larger.
Another example of how more information or information about the supply chain can be transmitted is provided by Faller Packaging: The secondary packaging specialist uses smart labels based on printable sensors. These indicate changes when they are exposed to certain influencing factors: For example, the print colours change if the temperature exceeds or falls below limits (thermochromic) or if the medicine has been exposed to too much light (photochromic).
The BS-300 blister machine allows quick and easy format changeovers.Flexibility is required
However, adherence, compliance and covenience are not the only trends currently characterising the development of pharmaceutical packaging. The desire for small batch sizes and flexible production quantities and formats is also becoming ever stronger as a result of the personalisation and specialisation of medicines. Flexibility and modularity are therefore key requirements in order to be able to process intelligent packaging efficiently and precisely. These requirements are met, for example, by a new top-loading machine for vials in table-top design, which Schubert-Pharma is presenting at ACHEMA: Flexibility in performance, fast batch changes and a high level of user-friendliness were at the forefront of its development.
The customisation of medicines requires smaller production batches and more frequent changeovers of packaging lines. Machines such as the ALF 5000 V recently presented by Syntegon are a flexible solution for filling high-priced products, which enables the combination of two filling systems on one platform. This makes it suitable for both large and small quantities. Syntegon has also taken up the desire for flexibility and small batch sizes in the development of the new RMA, a machine for assembling pens and autoinjectors. The space-saving, semi-automatic assembly machine is used for clinical studies and small batches and supports pharmaceutical companies in determining the properties of their administration systems and assembling them in accordance with regulatory standards. Harro Höfliger is also focussing on flexibility in the assembly of medical products: at Achema, the machine manufacturer presented a highly flexible assembly concept for changing requirements.
At FACHPACK 2024, Heino Ilsemann will be exhibiting a blister machine (BS-300) that enables simple and fast format changeovers – this means that even small production batches can be produced economically with frequent batch changes. Horizon will be showing the AF-408F, a folding machine for leaflets that can be changed over in a matter of seconds: Creasing tools are positioned automatically. Christ Packaging Systems is also focussing on flexibility with the Boxteq folding carton cartoner: the modular machine is designed to allow format changeovers within 20 minutes and thus simplify the changeover between formats, blisters, tubes, pouches, vials, syringes and other packaging materials.
Sustainability is becoming increasingly important in the packaging of pharmaceuticals.The VSM 500-X vacuum packaging machine, which MBM innovations will also be exhibiting at FACHPACK, allows not only format but also location changes: The semi-automatic flow-wrapping machine is equipped with suction nozzles that automatically adapt to the bag width – thus ensuring flexibility.
Sustainability as a driving force
Sustainable packaging is no longer an option, but a must. The pressure to reduce the ecological footprint is not only increasing due to regulatory measures, but also due to the sustainability goals of pharmaceutical companies. As the interface to the consumer, packaging plays an important role – also for image reasons. The Blister Pack Collective, initiated by PA Consulting and PulPac, uses a dry moulded fibre (DMF) to develop blister packs that are low in plastic. Well-known members such as Bayer and Sanofi are already supporting the collective as members. In future, packaging machines will increasingly have to be able to process environmentally friendly materials.
Uhlmann Pac-Systeme is addressing the issue of sustainability with its new PTC 200 Parenteral Tray Centre cartoning line: it safely packs ampoules, vials, syringes, pens and other devices in sustainable, recyclable plastic or cardboard trays and folding cartons.
Digitalisation and automation for greater efficiency
Digitalisation and automation play a key role in increasing efficiency in pharmaceutical packaging. Digital tools such as the IMA Sentinel service platform enable real-time monitoring of production processes and help to minimise errors and maximise efficiency through AI-supported data analysis. Such monitoring systems are also becoming increasingly popular in the pharmaceutical industry in order to fulfil the stringent requirements of the regulatory framework.
The integration of artificial intelligence (AI) into the packaging process could be the next milestone in the digitalisation of pharmaceutical packaging machines. For example, in the inspection of primary packaging. Syntegon uses AI, for example, to detect particles in liquids with a high degree of reliability.
Hygiene standards and containment in focus
Bausch+Ströbel recently demonstrated that digitalisation and automation can also be a key to greater hygiene in the process: Machine modules in which liquid medicines are packaged sterilely completely without gloves. The machine concept, called “Genex”, was specially developed for small batch sizes: Individual modules can be combined individually to form complete process chains. The development shows that flexibility and containment do not have to be a contradiction in terms when it comes to packaging machines.
Conclusion: The demands on pharmaceutical packaging machines are increasing. Packaging machine manufacturers are responding with innovative solutions that focus on flexibility, sustainability and digitalisation.
