Bilcare says about the future of pharmaceutical packaging innovations

A changing pharmaceutical industry

Changes in pharmaceutical industry research and manufacturing technologies have driven significant developments in packaging and delivery systems. An increase in the number of large-molecule, bio pharmaceutical drugs in development pipelines has led to an increase in the need for injectable packaging and administration systems. The old glass and elastomer closure systems may not provide the effective barrier properties needed for high-value, life saving therapies. Component manufacturers have responded with new materials and technologies that ensure extended drug-product shelf-life. Many new biotechnology-derived drug therapies are unstable in liquid form and therefore are introduced as lyophilized or dry powder dosage forms. Lyophilized drugs need special stoppers for optimal performance in lyophilization chambers. The stoppers must solve the problem of the stopper sticking to the lyophilization shelf after the cycle is completed. In addition, lyophilized drugs typically are reconstituted at the point of care, thus requiring patient-friendly administration systems.

The increase in self-administered therapies

Decades ago, healthcare revolved around hospital care. Today, healthcare often revolves around the home - a situation that has largely resulted from cost constraints and the introduction of maintenance-type drugs for treating chronic conditions such as arthritis, cancer, multiple sclerosis, and other diseases that require frequent medication. Many of these maintenance therapies are delivered by injection, spurring a need for patient-friendly administration systems. These systems must ensure the potency of the drug, be tamper-evident, help deter counterfeiting, promote compliance with a dosing regimen, ensure dosing accuracy, and be as safe, easy to use and painless as possible.

An outgrowth of these changes is the move from the typical vial and disposable syringe to the prefillable syringe. With prefillables, dosing accuracy is ensured but they present some challenges for the industry. A pharmaceutical company needs a prefillable system that protects the integrity of the packaged drug product over time and will function as represented over the full shelf life of the drug product. The response from component manufactures was to develop syringe plungers with barrier films that minimize the interaction between the packaged drug and the components. At the same time, the industry has developed elastomers for molded plungers that maintain functional properties such as seal integrity, and break-loose and extrusion forces.

When self-administered drugs are in lyophilized or dry powder form, manufacturers must find methods or packaging systems that help prevent accidental needle stick injuries, inaccurate dosing, and drug spray-back. Manufacturers familiar with the drug administration process must provide delivery systems that simplify drug reconstitution, especially for non-professional caregivers.

Bilcare thrives to provide Innovative packaging solutions of drugs & medicines

Packaging innovation is the technique which is need of this hour when half of the goods and service which we receive on this end from the other, lack genuineness and anybody can rarely spot any difference in original and fake. And all because of ill practices like counterfeiting and cloning which didn’t even leave out the pharmaceutical industry. Packaging innovation ensures the security of medicines and drugs as they are considered as state-of-the-art strategies to cope with problems like counterfeiting.

Bilcare is the leading organization on global platform for delivering reasonable, sustainable and innovative packaging solutions to customers as it is a research driven company which focuses on its customers’ needs that ensures its security. Bilcare offer innovative packaging solutions via these segments:

1. Packaging material: Bilcare Research barrier films are manufactured keeping in mind their affordability and that’s too without compromising with the quality of same. They are designed to be offered to individuals in variety of colors, thickness and additional factors as per individual requirements which provide climate protection to your product. Pharma packaging innovation is no less than an excellence in blister packaging as Bilcare is producing a wide range of cold form foil along with thermoforming films to ensure the safety of end product. They have manufacturing sites not only in India but in Germany, USA and Singapore in order to meet the demand of their customers worldwide.
2. Research Services: BilcareOptima is the first scientific method for creating best packaging of pharma products by eliminating over packaging. BilcareOptima is called the packaging solution which is packed by science.

Bilcare is committed to create sustainable competitive advantages for their customers. They acquired INEOS 5 years back, which is a plastic film-making unit of petrochemical company and it helped the organization in improving their product range which offered high margin solutions and products. Now Bilcare is renowned globally due to this acquisition and because of its continuous efforts for providing the innovative packaging solutions to end customers and avoid counterfeiting.

Innovative packaging of drugs & medicines at Bilcare

With the advancement and misuse of technology, few unwanted practices like plagiarism, forgery, sham, imitation, piracy, falsification and counterfeiting have become a part of this world. Whether we want it or not, we are living with it, spending half of our hard earned money on counterfeit products. Packaging innovation is one of those solutions which are the measures to cope with the problem of counterfeiting and provide the end customer with original goods and items.

Bilcare is the leading organization on global platform for delivering reasonable, sustainable and innovative packaging solutions to customers as it is a research driven company which focuses on its customers’ needs that ensures its security. Bilcare offer innovative packaging solutions via these segments:

Packaging material

• Barrier films: Bilcare Research barrier films are manufactured keeping in mind their affordability and that’s too without compromising with the quality of same. They are designed to be offered to individuals in variety of colors, thickness and additional factors as per individual requirements which provide climate protection to your product.
• PPI: pharma packaging innovation is no less than an excellence in blister packaging as Bilcare is producing a wide range of cold form foil along with thermoforming films to ensure the safety of end product. They have manufacturing sites not only in India but in Germany, USA and Singapore in order to meet the demand of their customers worldwide.

Research Services

BilcareOptima: it is the first scientific method for creating best packaging of pharma products by eliminating over packaging. BilcareOptima is called the packaging solution which is packed by science.

Bilcare is committed to create sustainable competitive advantages for their customers. They acquired INEOS 5 years back, which is a plastic film-making unit of petrochemical company and it helped the organization in improving their product range which offered high margin solutions and products. Now Bilcare is renowned globally due to this acquisition and because of its continuous efforts for providing the innovative packaging solutions to end customers and avoid counterfeiting.

Innovative packaging: revolution in pharmaceutical industry

In this technology driven era everything and everybody is going through lots of changes & innovation, and so is pharmaceutical industry which is supposed to grow up to 5000 crores by the end of this year, especially its packaging industry because it is facing frequent changes so that it can match its pace with development and growth.

Trends in pharma packaging are influenced by packaging materials and packaging processes. The packaging innovation which is in trend involves Radio Frequency Identification, which can scan and locate the containers and crates hundreds of meters away from it. Its benefits pay off very fast as it is easy and sophisticated to be handled. Non-electronic laminates and labels monitor the shock and change in transition along with measuring the goods and items if they are subject to be accepted or not. It is a label of the size of a visiting card which is more reliable & accurate than manual indicators and it contains micro batteries as well. There are many pharmaceutical concepts emerging on regular basis which is boosting the packaging innovation and considering the environmental factors while packing the medicines is one of those concepts. It still focuses on packaging advances without compromising with the quality of product.

Safety cap bottles were introduced to keep the medicines and drugs out of the reach of children to avoid the adverse effect on them and to be senior citizen friendly. Responsive ink is used, to warn the user about something which might happen if the medicine or drug is not taken with care. It is used on insulin packaging, antibiotics and vaccines to warn the user. Anti counterfeiting packaging involves the use of bar codes and unique numbers on primary-secondary packaging has been made mandatory by the DGFT of India. Territory packaging which is easy for tracking and tracing serialization of exported drugs also comes under this mandatory packaging.

Packaging innovation in pharma industry is equally essential for the human kind like pharmaceutical products because the change and innovation is a symbol of proceeding towards the future which inculcates lots of advanced approaches which is indispensible for the growth of human race.

Innovative packaging of pharmaceutical products

Precaution is better than cure, and that is why the things we eat, drink or consume some other way, need to be safer than ever because it is going to affect our health directly. The packaging ensures the user that the product is reliable and safe to be used. The pharmaceutical industry is facing tremendous changes every day and its packaging is also going under innovation on a very large scale. There were times when pharma packaging revolves around conserving the quality of enclosed medication and there is a time where it involves tampering, counterfeiting and emphasizing on dosage schedule of product along with its dispensing accuracy.

Trends in pharma packaging are influenced by packaging materials and packaging processes. The packaging innovation which is in trend involves the followings:

1. RFID: Radio Frequency Identification can scan and locate the containers and crates hundreds of meters away from it. Its benefits pay off very fast as it is easy and sophisticated to be handled.

2. Non-electronic laminates: these kinds of laminates and labels monitor the shock and change in transition along with measuring the goods and items if they are subject to be accepted or not. It is a label of the size of a visiting card which is more reliable & accurate than manual indicators and it contains micro batteries as well.

3. Responsive inks: it is used to warn the user about something which might happen if the medicine or drug is not taken with care. It is used on insulin packaging, antibiotics and vaccines to warn the user.

4. Anticounterfeiting packaging: use of bar codes and unique numbers on primary-secondary packaging has been made mandatory by the DGFT of India. Territory packaging which is easy for tracking and tracing serialization of exported drugs also comes under this mandatory packaging.

Packaging innovation in pharma industry is equally essential for the human kind like pharmaceutical products because the change and innovation is a symbol of proceeding towards the future which inculcates lots of advanced approaches which is indispensible for the growth of human race.

Recent Packaging Technologies

Blow-fill-seal technology

Aseptic blow-fill-seal (BFS) technology is the process by which plastic containers are formed, filled with sterile filtered product and sealed in an uninterrupted sequence of operations within the controlled sterile environment of a single machine.

The blow-fill-seal process is a robust, advanced aseptic processing technology, recognized by worldwide regulatory authorities for its inherent operational advantages over conventional aseptic production. Blow-fill-seal systems offer a unique combination of flexibility in innovative packaging design, low operating cost and a high degree of sterility assurance. The machines require a minimum number of operating personnel and have a relatively small space requirement.

A variety of polymers may be used in the process, low and high-density polyethylene and polypropylene being the most popular. The innate ability to form the container/closure during the actual aseptic packaging process allows for custom design of the container to meet the specific needs of the application. This flexibility not only improves container ease of use, but provides a means of interfacing with many of today's emerging drug delivery technologies, most notably in the field of respiratory therapy.

Blow-fill-seal process

Container moulding

Thermoplastic is continuously extruded in a tubular shape. When the tube reaches the correct length, the mold closes and the parison is cut. The bottom of the parison is pinched closed and the top is held in place with a set of holding jaws. The mold is then transferred to a position under the filling station.

Container filling

The nozzle assembly lowers into the parison until the nozzles form a seal with the neck of the mold. Container formation is completed by applying a vacuum on the mold-side of the container and blowing sterile filtered air into the interior of the container. The patented electronic fill system delivers a precise dosage of product into the container. The nozzles then retract into their original position.

Container sealing

Following completion of the filling process, the top of the container remains semi-molten. Separate seal molds close to form the top and hermetically seal the container. The mold opens and the container is then conveyed out of the machine.

The cycle is then repeated to produce another filled container. The filled containers are tested and checked to ensure that they meet the very strict specifications laid down for such products.

The duration of the complete cycle is between 10-18 seconds, depending on the container design and the amount of liquid to be filled.

Brandpak Solution: Innovative Packaging solution at Bilcare

Our innovative packaging solutions enable product differentiation and marketing by providing a unique brand identity to products. Our teams work closely with customer marketing teams and product owners to understand their marketing concerns and provide ease of distribution and innovative packaging for brand protection.

Bilcare Research's Brandpak solutions help in problem diagnosis and provide packaging solutions that affect the customer's top-line using its unique and patented packaging materials and smart, expressive designs. 

It is our aim to innovate and develop pioneering packaging solutions to meet the complex needs of the pharmaceutical industry. With our integrated services, we enable clients to focus on their core business, i.e. development of new drug molecules, formulation development, manufacturing and marketing while we partner with them in the area of drug stabilization and protection. We help customers capitalize on upcoming trends, through products that maximize the commercial potential and efficacy of drugs.

Bilcare Research’s Brandpak technology helps in problem diagnosis and the development of solutions using unique and patented innovative packaging materials.

Brandpak Building Process

Brandpak Solution Offerings