4-in-1: How we crafted a bulk pack that splits into 4 durable mini packs

The challenge: A high stakes request

The client’s medication wasn’t a typical product; it was crucial for patients who might need immediate access to a dose during a sudden attack. The packaging had to find a delicate balance: robust enough for bulk distribution and strong enough to protect single doses when separated. Patients needed to tear off individual doses to carry with them daily, but these had to remain secure against environmental damage like moisture, heat, or impact. A purely single-dose approach would lead to loose packages scattered everywhere, creating a risk of losing doses. The challenge was clear: develop a multipack that kept doses secure together but allowed for easy, damage-free separation.‍

Our approach: Innovation from the ground up

We like challenges that require fresh thinking. This project demanded a solution that didn’t exist yet. We began by working closely with the client to understand their needs, the frequency of patient use, and the durability needed for both multipack and individual doses.

With a clear understanding of the requirements, we moved into the design phase. We envisioned a packaging system that could split apart cleanly, like a perforated sheet, allowing each piece to maintain the same protective qualities as the original multipack. The key was ensuring that every separated unit remained fully intact, providing maximum protection for the medication wherever patients took it.‍

Prototyping and testing: Building the solution

Once we had a concept, it was time to bring it to life. Our first prototypes focused on these main areas:

• Durability: Ensuring that both the multipack and the individual doses could withstand being carried in bags or pockets without being crushed.
• Ease of separation: Ensuring that patients could easily tear off a dose without damaging the remaining packaging.

Our initial design showed promise but revealed a flaw: the perforation system was too fragile, causing packs to tear too easily. We went back to the drawing board, refining the design to ensure a clean, controlled separation. After several iterations and testing, we perfected the system.‍

The result: A solution that delivers

The final product combined the client’s needs for a robust multipack with the convenience of individual doses. Patients could now carry a single dose safely in their pocket, knowing it would remain protected until they needed it. Meanwhile, healthcare providers could distribute the medication in bulk without compromising on safety. This dual-function packaging met the high standards required for both durability and ease of use, providing the best of both worlds.‍

Conclusion: A solution tailored to real-world needs

This project exemplified what we do best: listening closely, thinking creatively, and delivering solutions that address real-world challenges. Even the most complex packaging problems can be solved with the right approach. If you’re facing a packaging challenge, we’re ready to help you find a solution that works!