Popular New Liquid Packaging Trends in 2018

 

Contract filling and packaging solutions for liquids cover everything from food and non-food substances to over-the-counter (OTC) medications, pharmaceuticals, and more. The large size of different companies in need of these services has introduced new liquid packaging trends that are now being embraced by companies around the world.

Turnkey packaging solutions and multi-layer containers are two such examples commonly found in the current market. Both of these are direct responses to consumer demands and prove that the company selling the product is listening to their customers. Let’s examine all of the latest liquid packaging trends by covering the different benefits each individual trend offers.

The Rise of Turnkey Solutions

Turnkey solutions are becoming the norm for pharmaceutical companies in need of packaging their medications and OTC products. Contract packagers have evolved into a multi-billion dollar industry and their growth is only projected to increase year to year. This is a direct result of their all-in-one services that not only achieve the desired results but at a reduced cost. In other words, it is the better investment for growing companies.

Key benefits include:

  • Cost-reduction
  • Scalability
  • Quality assurance
  • More eco-friendly
  • Maximum value
  • Standard regulation compliance

Tip: Since turnkey solutions are among new liquid packaging trends, more companies are trying to quickly adapt. Choose your turnkey partner by verifying their history and looking for a proven track record of success first.

Creative Custom Packaging Designs

Knowing the consumer market is key when deciding on the package design. For example, organic items have been the preferred choice for consumers across most industries. This preference has revealed a simple pattern in labeling. In essence, the more modest and natural the packaging seems, the more appealing it is to customers.

Other packaging and label preferences include:

  • Functionality (Is it portable/ sealable/ recyclable/ etc.?)
  • Clear / transparency (Can you view the product through the container)
  • Eco-friendly (Does it reduce overall environmental impact)
  • Vintage labeling (Can you revive an older design for nostalgic appeal?)

Tip: The most important aspect to deciding on the packaging design and labeling is to know who you are marketing it to. Bold is not always better and a minimal design strategy can save you money.

Embracing New Technology

The improved capabilities of automated contract filling machines are equally economical and practical. Why potentially risk damaging your product during the filling process when it is unnecessary? The temperature when sealing can damage or negatively affect the product’s quality. Moreover, more companies are in need of small batch product sizes than ever before.

Contract filling services using injection molding technology during the blow, fill, seal process eliminate this risk and new, automated contract filling machines are capable of both full-scale and small batch production. What this means is you can eliminate paying excessive labor costs if you need to.

To learn more about the advantages of contract filling using injection molding, check out Contract Filling Equipment for more information.

 

To discuss these liquid packaging trends or to speak with someone about the advantages of using a turnkey partner connect with us or contact LF of America today.

A member of our team will be more than happy to find the perfect packaging solution that brings your company into its next phase of success.

 

JVNW Pharmaceutical Vessels

The processing of sterile and non-sterile liquids, such as blood plasma have specific purity requirements that can only be achieved with great technical skill and experience. Preparation and pressure vessels from JVNW are built to meet all standards and ensure that our customers ‘central process components’ have competitive advantages. The surfaces of JVNW’s preparation and pressure vessels are ground and polished, and as required, electro-polished. All welds are smoothed to the current GMP-/ FDA-standards and exclude even the smallest cleaning dead spaces.

All vessels can be supplied as stand-alone equipment (stationery or mobile) or as automated process units delivered as fully-functional modules installed on-site that include: agitators; homogenizers; metering and regulating technology; control units; valves and pipe connections. Options for hazardous environments are also available.

JVNW provides high quality storage and transportation vessels made of stainless steel. Each vessel is designed to the specific customer´s requirements. JVNW builds full scrape vessels with off-set turbines, dual motion full scrape tanks with counter-rotating turbine agitators and bottom sweep mix tanks. Fixed position spray-balls are custom drilled to match each tank and are tested for complete Sterilization-In-Place.

Bonfiglioli in Minnesota

 

We are delighted to announce that as of Monday June 25th we will be travelling around Minnesota accompanied by Bonfiglioli’s Product Specialist Piero Polastri.

Due to the opportunity of our Project Managers being in your close proximity, we strongly encourage you giving us a call and getting your name on our site visits calendar.

 

This Bofiglioli Demo Tour will uncover some insights on the just released new SAIL machine.

The Bonfiglioli Engineering SAIL puts Container Closure Integrity Testing, Visual Inspection and HGA all on one tabletop making it the ideal solution to ensure Quality and Safety of Parenteral Packages and verify:

– Presence of leaks

– Headspace gas content

– Absence of visible foreign materials.

It is suitable for in-process control, clinical trials and laboratory use without altering the container features. Testing is quick, reliable and repeatable, and gives consistent results for a comprehensive batch control.

 

SAIL stands for Smart Automated Inspection Laboraty meaning that the machine is an automated inspection laboratory especially designed to conjugate sensitivity performance, productivity as well as flexibility to inspect different container types, sizes and contents. A single machine designed to provide customers with a comprehensive set of benefits.

 

Based upon the Bonfiglioli Engineering state-of-the-art proprietary technologies, SAIL is fully customizable in order to best meet present and future user needs and cover a wide range of inspection requirements.

It is characterized by complete modularity and flexibility, including one or more stations for Automatic Visual Inspection to perform any kind of foreign particles detection, cosmetic analysis and cap control at 360°. Additionally, it can integrate stations for Vacuum-Decay based CCIT and Laser-Based HGA for Oxygen/Moisture/CO2/ Vacuum level control, thus making this product an all in one inspection solution suitable for various production facilities.

 

If you want to get some early insights on the SAIL machine as well as on other products off the Bonfiglioli Engineering product line get in touch with Joe Skorcz at JoeS@Lsi1.com or 312-545-2164.

 

Don’t miss out on the opportunity to be first in line to learn more about the newest innovation in the automation inspection for various containers.

Bonfiglioli Engineering unveiled the brand new SAIL – SMART AUTOMATED INSPECTION LABORATORY for pharmaceutical applications.

Earlier today, Bonfiglioli during the opening hours of this year’s Achema Expo in Frankfurt, Germany unveiled their latest product for the pharma applications. It is capable of performing multiple in line inspections on the same package container. By design it features in line leak detection, visual container inspection and laser analysis.

To learn more about the Smart Automated Inspection Laboratory – SAIL give us a call or contact MarkoV@Lsi1.com

Bonfiglioli Engineering will be attending ACHEMA 2018 trade fair.

 

What makes this year exceptional is the world premiere of a revolutionary product in the inspection field, which will enable the pharmaceutical companies and laboratories to reach an unrivaled competitive advantage never seen before, will take place during the exhibition.

You’ll just have to come and visit Bonfig at Booth C70 – Hall 3.1 by following the “Flexible Production” indications to discover the Bonfiglioli Engineering extraordinary innovation of 2018.

More teasers of the product that will be unveiled at the ACHEMA can be found here: http://www.bonfiglioliengineering.com/news/achema-2018

 

 

Fedegari will be exhibiting their latest developments on contamination control to help customers achieving cost-effectiveness with the best performances in pharma manufacturing.

You will be able to see the integration of different Fedegari processes and technologies, as Fedegari has developed fully integrated robotized solutions for different customers world-wide helping them to achieve the best performances and increasing cost-effectiveness.

Be prepared… you will be pleasantly surprised by this exclusive Italian manufacturer, that has prepared a show that you’ll cherish forever.

For this Achema, Bruno has created an exclusive menu for Fedegari. Bruno’s special dishes express his creativity through the quality of carefully selected ingredients: just as Fedegari does, everyday, when we build our engineered process equipment.

See more about Fedegari’s show roadmap at: https://www.achema.fedegari.com/

Curious? Come and visit Fedegari in Frankfurt, Hall 6.1 – Booth B6

 

Lameplast Group, the parent network of LF of America will be settling in Hall 1.1 D48.

Lot of innovations are waiting for you: new primary plastic containers, the brand new models of Pentafill Filling & Sealing Machines, the global services dedicated to pharmaceutical industries and the newest products ready for the distribution.

A great addition to Lameplast’s services is the new filling department for sterile products with fully-automated filling and packaging lines has been opened, set in Boca Raton Florida. The eco-friendly department has been built according to the best process technologies available, and is currently being reviewed for FDA compliance. The new US based camp should be an exact copy of the Italy based contract filling facility that houses a ISO 5 compliant cleanroom, suitable for aseptic automated filling in their COC Farmaceutici plant in Modena, Italy.

LF is an exceptional company and what makes them unique on the market is the fact that they offer Product Development as part of their services. The actual in lab product development main intent is to improve the flow and specification of the product by customizing it to fit the packaging and delivery method emphasized by LF & Lameplast.

Don’t’ miss them!

 

FLEXIBLE ISOLATION TECHNOLOGY INTEGRATED TO FILLING LINES by Fedegari for BSM

 

Berkshire Sterile Manufacturing (US) can be considered the unique CMO that incorporates 100% isolator technology to the filling lines utilizing state-of-the-art equipment. This technology allows to remove the risk of human contamination from the filling and formulation process as highly suggested by FDA, EMEA and other regulatory bodies. Fedegari has proudly collaborated with BSM on engineering a cost-effective and innovative solution that helps pharma industries to advance their product candidate into the pre-clinical or clinical setting.

The result of BSM-Fedegari collaborative innovation is an isolator based filling system that is able to fill the following primary containers: bulk glass vials, pre-sterilized nested vials (glass and plastic) and syringes (glass and plastic), pre-sterilized nested cartridges (glass and plastic), and custom containers (glass and plastic). The system works with both liquid and lyophilized products and the primary containers do not have to be exposed to hydrogen peroxide before entering the isolator.

 

 

Flexible Isolation technology totally integrated to the filling lines

BSM flexible clinical scale aseptic filling system does not restricts the choice of the container and has been considered a revolutionary solution by pharma manufacturers.‘Isolator-based ‘flex’ lines capable of multiple containers have been used by some industries, but most are unable to accommodate bulk glass vials and some require previous treatment with vapour hydrogen peroxide for all primary container packaging,’ said BSM CEO Shawn Kinney.

 

‘With this project BSM is definitely one of our most forward-looking customers. I hope that the experiences we are doing together will enable pharmaceutical manufacturing to reach new efficiency standards’ commented Giuseppe Fedegari, President of Fedegari Group.

“We are pleased to provide to our clients and our future clients the best available technology for their sterile manufacturing requirements”, stated BSM CEO Shawn Kinney.

 

BSM COMPLETES VALIDATION OF STATE-OF-THE-ART ISOLATOR

Berkshire Sterile Manufacturing (BSM) has just completed the installation and qualification of its Freeze Dryer IMA Lyomax 3 connected to BSM’s Fedegari Isolator Line. The last step to complete this innovative project will now provide BSM clients the highest levels in sterility assurance. The qualification involved extensive IOQ’s of the equipment, validation of the SIP and CIP and media qualifications that utilized three complete loads. The validation involved BSM’s Colanar Flexible Filler, capable of filling vials, syringes and cartridges on the same line. BSM completed the isolator qualification with over 12,000 units/run in triplicate with filling duration’s of over 60 hours per run.

CUTTING EDGE TECHNOLOGIES GUARANTEE COST-EFFECTIVENESS

The Berkshire Corporate Center (US) is equipped with cutting edge manufacturing technologies – including Fedegari process equipment – such as isolators, flexible sterile filling equipment, modern cleanroom and terminal steam sterilization capabilities to manufacture sterile drugs.

BSM’s Fedegari autoclave, for example, has the capability to terminally sterilize syringes, bags, vials and ampules with a 20,000 unit load capacity. The autoclave has internal heat exchangers that can be used to warm the chamber by putting steam through prior to starting a cycle. This eliminates the condensation that normally occurs on the walls of the chamber during standard heat up with common autoclaves in the market.

 

To speed up turnaround times BSM’s autoclave is also equipped to use the heat exchangers with cold water to cool the load while pulling vacuum to dry the load. Less condensation of steam increases efficacy of the sterilization process while also reducing time of the product or equipment in the autoclave.

 

The complete data of the case study and a photo gallery showcasing Fedegari’s latest Isolation technology can be found here: https://www.fedegari.com/en/berkshire-sterile-completes-validation-of-flexible-isolator/

 

FDA rolls out action plan to improve medical device safety

The FDA released The Medical Device Safety Action Plan April 17, which outlines agency strategies to better monitor and regulate the safety of medical devices.

The agency hopes the plan will spur more innovation for device safety, help identify safety risks earlier, and keep physicians and patients more informed.

“Our aim is to make sure that the new advances in technology that are enabling better capabilities and benefits are also harnessed to bring added assurances of safety, so that more patients can benefit from new devices and address unmet needs,” FDA Commissioner Scott Gottlieb, MD, said in a statement about the program.

Here are five goals the agency seeks to achieve through the plan.

  1. Establish a robust medical device patient safety net in the U.S.
  1. Explore regulatory options to streamline and modernize timely implementation of postmarket mitigations
  1. Spur innovation toward safer medical devices
  1. Advance medical device cybersecurity
  1. Integrate the FDA Center for Devices and Radiological Health’s premarket and postmarket offices and activities to advance the use of a total product life cycle approach to device safety

To learn more about the action plan, click here.

Source: https://www.beckershospitalreview.com/supply-chain/fda-rolls-out-plan-to-improve-medical-device-safety.html

Warehouse Mapping-Mesa Labs

The changing weather can greatly impact certain areas of your warehouse, and these temperatures changes may affect your product. Will temperature mapping your warehouse only once provide enough information to understand the storage conditions in the warehouse during the coldest time of the year (high use of heating) and warmest time of the year (high use of A/C) or should your warehouse be mapped multiple times so that your products are not potentially damaged?

Mesa’s Compliance and Validation Services experts will work with you and your team to review every potential variable that may impact the viability of your product. We will determine the risk factors by considering all HVAC activity and control, loading dock location and activity to develop criteria for and execution of a thermal mapping.

We will also establish acceptance criteria. The temperature and relative humidity acceptance criteria for each product is determined by testing conducted per the FDA Guidance Document – Stability Testing of New Drug Substances and Products, or similar guidance. The data logging system will be determined, a diagram will be developed, and the length of the study will be defined. Finally, Mesa experts will place the data loggers in the appropriate locations throughout your warehouse and collect the resulting data.

By performing regular mappings of your warehouse, you can greatly reduce the risk to your products by varying temperatures when the seasons change.

LATEST DEVELOPMENTS: INTEGRATED SOLUTION FOR STERILE ANTIBIOTICS

Fedegari Group was chosen as the preferred supplier of contamination control systems for a multinational pharmaceutical company with a new sterile antibiotic powder plant. The main challenges of the customer were to optimize the powder filling process and benefit from the cost-effectiveness of process integration with the best ergonomic design for the operators as well as ensuring a reliable and safe pharmaceutical process.

 

Cost-effective Solution for Filling Al-kegs with Sterile Antibiotics

Fedegari Engineering Team has worked with the customer for developing the most efficient and reliable solution that would allow to fill the containers (kegs) in the safest way for the product and for the operators. The outcome is a complete plant that combines in a modular way various subsystems which have been individually tested by Fedegari for different applications thus minimizing the risks typically associated with novelties. The solution also represents the most compact design for this type of operations.

 

Filling Al-kegs with Sterile Antibiotics

Fig. 1 – Removing the Al-kegs from the washer rack

 

Fedegari was choosen as the only manufacturer able to supply the process equipment (Washer-sterilizer) integrated with RABS and surface bio-decontamination with hydrogen peroxide MAL (Material Air-Lock).

The Project

A Washer-sterilizer integrated with RABS and bio-decontamination with hydrogen peroxide MAL applied to the system. The washer unloads on module 2 – RABS.

Module 1: Washing-sterilization

Module 2: Washed kegs unloading station

Module 3: Empty kegs buffer station

Module 4: Manual powder dosing, capping and bagging with automatic pneumatic lifting device. Packaging materials and tools are introduced through the hydrogen peroxide MAL connected to the module.

Module 5: Filled and packed kegs unloading station

Thema4 process controller delivered to the customer will be completely integrated with SCADA system.

Cost-effective Solution for Sterile Antibiotic Powder Filling of Al- kegs

Integrated Solution for Sterile Antibiotic Powder Filling of Al- kegs

Cost-effectiveness & Results

This solution helped the customer to achieve the desired ergonomic results on manual operations reducing the risks of contamination due to the integration of different machines connected by the RABS into one unique system managed by a single process controller.

 

ERGONOMIC DESIGN – Unloading system designed to work at the same level (height) throughout all the modules – from the washer to the RABS.

 

SIGNIFICANT TIME AND COST-SAVINGS by easily handling the kegs through sequential workflow inside the RABS.

 

CUSTOMIZATION – Modular & custom-made loading racks

 

COST-EFFECTIVENESS – Time and cost-savings on training and maintenance due to standardization of components, procedures and process controller.

 

Fresenius Kabi Specify Newman Vial Labeller For Reliability And Output

Newman Labelling Systems, a leading manufacturer of pharmaceutical labelling systems, has supplied a 6VAL labelling system to health care company Fresenius Kabi for use in their Port Elizabeth facility in South Africa.

The 6VAL labelling system is designed to apply both clear and paper self-adhesive labels to a range of rigid cylindrical containers. At Fresenius Kabi it is being used to label 2ml vials of PETOGEN 150mg/mL Injection. The well proven 6VAL container handling system is specifically designed for handling unstable containers such vials, in addition to ampoules, syringes and cartridges, at speeds of up to 275 containers per minute.

The 6VAL has been supplied by Newman with a PCE Pilot Optical Character Vision and Optical Character Recognition system and a Videojet Dataflex Thermal Transfer Coder with colour screen for printing batch and expiry dates.

Fresenius Kabi’s decision to purchase the 6VAL was based on a combination of machine quality and capability, plus the reputation of Newman Labelling Systems both within the company and the industry at large. Jeremiah Thorne, Project Engineer at Fresenius Kabi, explains: “We were impressed by the output capacity of the machine, the presence of a unit rejection station, 2D barcode scanning option and the fact that it is cGMP compliant. We also liked Newman’s ability to supply the machine with OCV and OCR options.

“The other consideration in our decision was the brand name and the manufacturer’s expertise when it comes to developing and manufacturing labelling equipment for vials and ampoules. Newman’s machines have proved to be reliable and Newman has always provided a professional, efficient and helpful service, which has led us to standardise on them in our factory. “

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