clinical supply services

case study
Uhlmann ups1030et
The Blister Packaging Cost Advantage
Executive Summary
A client, in need of global blister packaging, had received an exorbitant estimate
from a Clinical Packaging and Logistics provider other than Catalent. In view
of severe budgeting constraints, the client was searching for more economical
pricing and turned to Catalent. In addition to being able to provide exceptional
cost efficiencies, Catalents team of clinical packaging and logistics experts
includes professionals who bring a wealth of highly specialized experience
in blister packaging. The original estimate from the other provider totaled
$794,500 and included $557,000 for packaging and labeling; $37,500 for film
and foil; and, $200,000 for blister card stock. By engineering a customized
package design and through the use of specialized Uhlmann UPS1030ET
equipment, Catalent could complete the project at the following costs: $325,250
for packaging and labeling and $50,000 for film and foil for a total cost of
$375,250. The client could count on a staggering cost savings of $471,750.

The customized Uhlmann ups1030et commercial platform is used to produce

state-of-the-art blister packaging. Catalent can develop a custom blister
packaging design, using many of the equipments optional features.

Catalent has a record of success in packaging multiple visually identical

products into finished blister packages ready for labeling. Since flexible master
formats exist, easy configuration of blister packaging is possible, providing a
quick start-up, and ensuring a reduced set up cost. Catalent has had repeated
success in completing complex blister packaging projects on schedule.

The Challenge
The client was overwhelmed by a previous estimate that was submitted for blister
packaging. When Catalent was challenged to reduce costs without compromising
the full extent of required services, Catalent turned to customized Uhlmann
UPS1030ET equipment. Consistently, this sophisticated technology has enabled
a more efficient process that lowers packaging and labeling costs and eliminates
hard seal card stock and processing expenses. A significant challenge is the
engineering of a child resistant blister package that allows for package integrity,
without separating each dose. The blister packaging must be user-friendly, easily

DEVELOPMENT DELIVERY SUPPLY

 accessible and must have a CSPC recognized child resistant feature. The design
must also provide for the complex feeding of visually identical multiple products,
and allow for enough real estate for large clinical booklet labels. Catalent is able
to overcome project challenges through a combination of exceptional equipment
and many decades of combined experience in supplying clinical blister packaging.

The Catalent Solution

Engineering the design
Typically, the Catalent design team initiates the project by engineering user-
friendly blister packaging (figure 1) that makes the visually identical tablets
easily accessible. Clients have the benefit of Catalents previous experience in
designing blister packaging with up to four different visually identical products.

cavity seal

21.40

21.30

21.30

21.30

21.30
label area
product seal area
21.40

37.40 37.30 37.30 11.00 37.30 37.30 37.40

figure 1

figure 2

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 Catalent uses one of their two Uhlmann UPS1030ETs to complete the
packaging in a single integrated process (figure 2). An extended Feeding
Area provides the necessary spatial separation for multiple product blistering.
Custom PLC controls enable efficient start and stop operations with two
servo-driven indexes to maintain registration. External web guiding allows
for format flexibility and multiple Simtap automated feeders can deliver high
speed feeding of multiple blister packaging. Other equipment features are:

CSAT digital printing with UV curing for dosing graphics

Lot-expiry data and unique packaging identification

Lid elongation to maintain registration of reprinted and in-house printed lid material

VisioRead OCV/OCR Inspection system to confirm text

and graphic content, quality and position

VisioChrom HR Product Inspection system to optimize

the inspection of minor product defects

Pinhole detection of Cold Formed (Alu) cavities

Typical peel and push packaging

Shown here are examples of Catalent designed blister packaging (figures 3 and
4). The packaging features lid side accessibility for a 4 tablet per day/9 day trial.
Kiss Cut perforation tools are used to score the lid so that the Peel and Push
Child Resistant Feature can be employed without the separation of each dose.
This means that the unused investigational medication that must be returned to
the sponsor is received back intact with the clinical label for final accountability.

figure 3 Cavity Side of Typical figure 4 Lid/Access Side of

Peel and Push Package Typical Peel and Push Package

figure 5

Optional package 4 tablet per day/9-day trial

In optional packaging for a 4 tablet per day/9 day trial, tear up corners (sweeps)
make for easy access. Universal coding is used (figure 5) when trials are

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 conducted in multiple countries. In similar cases, images of the Sun or Moon have
been used to communicate the time of day that the tablet should be administered.

Kiss cut perforation

Kiss Cut perforation tools can score the packaging without cutting through the card
(figure 6). An easy to peel, child resistant, foil layer helps in protecting individual sections.

Puncture and access option

Having achieved the safest CR rating of FI by actual child testing, the Puncture
and Access option eliminates wasted package space and additional set-up cost
required for the cutting of Peel and Push CR packages. This CR feature provides
novel foil protection on the back of the folding wallet size card (figure 7) and
increases the difficulty for small children to access the trial medication.

figure 6

figure 7

Conclusion
Customers turn to Catalent for blister packaging projects because of the impressive
cost savings they can achieve. The Uhlmann UPS1030 ET that Catalent employs can
perform multiple functions that save time and money. Beyond this technologically
advanced equipment, customers can rely on custom designed solutions provided
by a team of blister packaging experts. These Catalent professionals bring decades
of experience to each project, working with clients under the leadership of a project
manager. A spirit of teamwork drives the project, and gets on time results, every time.

Discover more solutions with Catalent.

Call: + 1 888 SOLUTION (765-8846) Email: solutions@catalent.com Visit: www.catalent.com

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