The throat lozenges of the Dr Pfleger Arzneimittel GmbH relies on the natural power of primrose root. For packaging development, the company relies on the plastics expertise of Partner Pöppelmann FAMAC. The packaging specialist was commissioned to revise the existing Ipalat-pastille tin and was able to convince from the first draft to series production.
„Now with a pop-top“, announces Dr Pfleger Arzneimittel GmbH in adverts for its tried-and-tested throat lozenges for hoarseness and coughing. The fact that these have been in modernised, user-friendly packaging are offered, is Pöppelmann FAMAC, a division of the Pöppelmann Group from Lohne. The plastics specialist was awarded the contract by Dr Pfleger for the development of the new Ipalat closure thanks to its comprehensive range of services.
The FAMAC division specialises in technical functional parts and packaging, including for the pharmaceutical industry and medical technology. Its core competences include the Development of customised packaging made from high-quality plastic parts, which are characterised by special functions, for example. At Pöppelmann FAMAC, all process steps - from development and series production to packaging - take place under one roof. This complete package convinced the pharmaceutical manufacturer.
„Our customer Dr Pfleger had the following questions regarding the revision of the Ipalat packaging very concrete ideas. A tamper-evident closure with a one-handed opening was required for the new development. Other requirements included improved hygiene when removing the pastilles and simple, user-friendly dosing of the preparation. In addition, the closure had to ensure a tight fit with a high degree of leak-tightness on the can, be food-safe and permanently odourless,“ explains Sebastian Hannöver, project manager at Pöppelmann FAMAC.
Equipped with these specifications, the plastics specialist embarked on product development. Pöppelmann FAMAC uses innovative development and design tools to create a product that fulfils all customer requirements and can be produced economically in large quantities. Each process step is carried out in close consultation with the customer.
State-of-the-art processes such as CATIA V5, structural calculations (FEM), filling analyses, 3D simulation and digital mock-up (DMU) are used to create computer-generated test models. In terms of design, the developers at Pöppelmann FAMAC follow the Guidelines of the universal design concept. Products should be designed sensibly and intelligently so that they can be used by as many people as possible without instructions. Functionality, ergonomics, the right choice of materials and user interfaces are just as important as aesthetics, marketability, market potential, feasibility, degree of innovation and sustainability. „Everything comes together with the respective project manager, who coordinates the customer's wishes and specifications with our specialist departments and is the direct point of contact for our customers,“ explains Sebastian Hannöver.
Continuous quality assurance through all process phases
If a product such as the Ipalat packaging is to go into series production at Pöppelmann FAMAC, the highest demands are placed on technology and quality from the start of product development to the release of the mould design. The process at Pöppelmann FAMAC goes through Four phases of quality assurance using a quality management system that is certified in accordance with ISO 13485, Quality Management System for the Design and Manufacture of Medical Devices. The manufacturing process is checked and documented in detail across all phases of industrialisation.
In the first phase, the Design Qualification (DQ), the requirements for the component are specified in the specifications and implemented by selecting a suitable mould concept. Once the mould has been completed, the next step is the Installation Qualification (IQ) checks whether it has been created in accordance with the DQ specifications. At the same time, test plans are agreed with the customer. This is followed by the Operational Qualification (OQ), which is used to determine a safe process window. The process parameters are determined and documented with regard to their effects on the component by means of DOE (Design of Experiments) tests. As part of this functional qualification, both the performance of the mould and the machine capability are examined. Finally, the phase of Performance Qualification (PQ): In this qualification step, the process and its influencing parameters are known as well as possible. The process capability of the component is determined and assessed. Once the PQ has been completed, the component is released for series production.
Development steps of the new Ipalat packaging
In order to get a precise idea of the designs for the new packaging closure created at Pöppelmann FAMAC, those responsible at Dr Pfleger took advantage of the service Rapid prototyping in use. This is because the plastics specialist offers to realise designs with the help of additive manufacturing „tangible“ and thus make it easier for customers to make decisions. The various additive manufacturing processes offered by the Pöppelmann Group make it possible to reproduce products with complex structures in detail and to use different materials for this purpose.
The process can then be used to produce functional samples or even small series. With the help of the CAD data, a detailed prototype of the closure was built for the Ipalat project using in-house 3D printers. „During the development phase, we used the rapid prototyping service to get a feel for the new closure at an early stage. Our experience was consistently positive: Pöppelmann FAMAC responded very quickly to requests for changes and produced new samples,“ explains Pascal Stein, project manager at Dr Pfleger Arzneimittel GmbH.
Once Dr Pfleger had decided on the optimum design, the In-house toolmaking The Pöppelmann Group was responsible for ensuring that the product was ready for series production. The department's technicians and engineers drew up a concept for the coordination of the first small series. Pre-series tool and then took over the production of a series mould in accordance with the applicable pharmaceutical standards.
Modern machinery was available for the series production of plastic parts. Here, the consistent Implementation of GMP standards a high degree of purity in the production of hygienic packaging from a pharmaceutical point of view. On customer request, Pöppelmann also offers the necessary prerequisites for the manufacture of products under clean room conditions, both in accordance with DIN EN ISO 14644, class 7 as well as class C in accordance with EU GMP guidelines.
Familiar can design - revised and with new functionality
The result of the redesigned Ipalat packaging is impressive: the Pöppelmann The solution developed by FAMAC consists of a slimmer, higher, altogether more visually elegant plastic box with a Hinged lid that can be operated with one hand, whose outer dimensions are flush with the edge of the pharmaceutical packaging. The lid, whose tamper-evident closure allows the user to First opening has a smaller opening than the previous version, which makes it even easier to dose the pastilles.
„We are very satisfied with the result, which combines function, user-friendliness, safety and design with consistently high quality of the closures. The collaboration with Pöppelmann FAMAC is not only highly recommended on a professional level, but also the consistently pleasant, open and committed contact with everyone involved in the project was very pleasing and convinced me that I had chosen the right partner,“ says Pascal Stein looking back.
Sebastian Hannöver adds: „One of Pöppelmann FAMAC's core competences is the development of customised packaging that is equally impressive in terms of function and design and economical to produce. We are delighted that we have achieved a result for Dr Pfleger that Convinced all round."
