Convincing in function, optics, and cost-effectiveness: Successful modernization of ipalat lozenge packaging by Pöppelmann FAMAC®

The ipalat packaging modernized by Pöppelmann FAMAC®: A slim plastic container with one-handed operable flip lid with authenticity seal. (Image: Pöppelmann FAMAC)

Pöppelmann FAMAC® successfully implemented the modernization of a packaging for throat lozenges for Dr. PÃleger Arzneimittel GmbH. Among the core competencies of the division specializing in technical functional parts and packaging of the plastics specialist Pöppelmann is the development of custom-designed packaging made from high-quality plastic parts, which convincingly combine functionality, design, and cost-effectiveness in manufacturing. The best proof of this: the new ipalat packaging.

The reason for the revision was Dr. PÃleger Arzneimittel GmbH's desire for the development of an original closure that allows one-handed opening and offers improved hygiene when dispensing lozenges. The closure, which fits securely onto the container, should provide simple, user-friendly dosing and ensure that the overall packaging is food-safe and odor-neutral. The implementation – from the initial draft to series production – was carried out at Pöppelmann FAMAC® in close coordination with the client, Dr. PÃleger, using innovative development and design tools.

All under one roof: From development to series production

State-of-the-art methods such as CATIA V5, structural calculations (FEM), fill analyses, 3D simulation, and digital mock-up (DMU) are used to create computer-generated test models. In design, the developers at Pöppelmann FAMAC® follow the guidelines of the Universal Design concept. It combines functionality, ergonomics, and the right choice of material properties and user interface surfaces. Additionally, the concept considers aspects such as aesthetics, marketability, market potential, feasibility, degree of innovation, and sustainability. To facilitate decision-making for Dr. PÃleger Arzneimittel, the in-house Rapid Prototyping service was used: Pöppelmann FAMAC® created detailed prototypes of the newly developed closure using additive manufacturing. The Pöppelmann toolmaking division produced a pre-series tool for the production of initial small batches and later the series tool according to current pharmaceutical standards. The series production of the new packaging then took place in compliance with applicable GMP standards. If needed, Pöppelmann FAMAC® also meets the requirements for manufacturing products in cleanroom conditions (DIN EN ISO 14644, Class 7 or EU-GMP guidelines, Class C).

Familiar packaging design, new functionality

The solution developed by Pöppelmann FAMAC® is a slimmer, taller, overall more visually elegant plastic container with a one-handed operable flip-top lid, whose outer dimensions align with the edge of the pharmaceutical packaging. An original closure guarantees the user the first opening. The lid has a smaller opening than the previous version, enabling better dosing of the throat lozenges. "We are very satisfied with the result, which combines functionality, user-friendliness, safety, and design while maintaining the high quality of the closures," says Pascal Stein, project manager at Dr. PÃleger Arzneimittel GmbH.