Solving a Complex Titration Packaging Challenge for a Commercial-Stage Pharmaceutical Product

Approach

At first, it was uncertain if we could create a solution that would accommodate all the requirements, as the request was extremely complex. We focused on the primary blister design, given the flexibility we had in this area. Our goal was to develop a solution that could meet all the demands: child resistance, the titration regimen, and fitting all 168 tablets into a single package. After finalizing the blister design, we moved into the prototyping phase, using the altered blisters to test several different overall packaging’s. As we progressed through this process, we became increasingly confident that we could fit all 168 tablets into one child-resistant packaging.

Titration regimen

After gaining confidence in our ability to fit all the tablets into a single child-resistant package, we faced the next challenge: managing the titration regimen. This added another layer of complexity, as the medication involved five different strengths, with varying tablet sizes and quantities. Fortunately, with our experience in handling titration packs—where the dosage increases over time—we were confident we could organize the packaging in such a way that would make the titration process intuitive for patients.

To manage the titration regimen effectively, we used our cold seal wallets, which allows instructions and information to be printed close to the medication, making the titration schedule easier for patients to understand. Each wallet held multiple blisters, and a total of three cold seal wallets were integrated into the packaging. This was the final hurdle to overcome (for us to provide our client with a solution that successfully accommodated all their requirements.)

Outcome

Through an intensive process of multiple prototypes, iterations, and meetings, we developed a packaging solution that met all of the client’s complex requirements. Our design allowed the 168 tablets to be securely held in a child-resistant package while ensuring that the titration regimen for all 168 tablets was still easy for patients to follow.

Takeaway Message

This case study demonstrates how innovation is at the core of what we do, not just something we claim. Faced with a challenge we had never encountered before, we pushed ourselves to think creatively and find the best possible packaging solution, while keeping every requirement in focus. It highlights our commitment to overcoming complex challenges, no matter how new or difficult they may seem. Even when the situation is unfamiliar, our drive remains to deliver practical, effective, and customer-oriented solutions.

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