Packaging
Focus on pharma & life science: For the glass and plastics specialist Gerresheimer the innovation engine is running at full speed
Monday 05. May 2008 - A more specialised, complex and demanding target area than pharma and life science could hardly be found anywhere in the entire market for packaging and application systems: it is primarily on this segment that Gerresheimer AG concentrates, and today it enjoys a reputation as one of the most versatile and highly innovative suppliers in the world.
Why progress in glass and plastic also means progress in pharmaceuticals and medicine and what level the development in this field has now reached is made clear by Gerresheimer at Interpack 2008 in Düsseldorf. Additional highlights are set by the company with designer glass for cosmetics and glass specialties (April 24 – 30, Hall 7, Stand A01).
Over recent years, Gerresheimer has developed with enormous dynamism. The company which has been listed on the stock exchange since mid-2007 ranks today among the small number of global players of its kind, with 41 production locations and almost 11,000 employees in Europe, America and Asia: more oriented than ever towards the globally operating pharma & life science industry, from which around two thirds of its sales result. Through its strategic acquisitions over recent years the Group has not only grown substantially in regional terms but also expanded its product portfolio.
In addition to the large special-glass divisions the carefully expanded plastics division is exhibiting as a highly competitive pillar of the business. And in both cases Gerres¬heimer has a technological lead – of which visitors to Interpack can obtain a comprehensive picture. “We are exhibiting brilliant innovations. In other regards as well we have lots of good news and background information. Im looking forward to this fair with particular anticipation, and expect a lasting positive reaction from all round the world to each of our product areas, “says Burkhard Lingenberg, Director of Marketing and Communication for the Group.
Gerresheimer for pharma & life science:
A unique spectrum across the board in glass and plastic
Prefillable syringe systems and intelligent accessories are at all events a special highlight from Gerresheimer. Especially with RTF (Ready to Fill) syringes which the company supplies to the pharma industry completely sterile and ready to fill it has for many years enjoyed a reputation as a pacemaker. Just last year the Group doubled its production capacity for sterile glass syringes at its competence centre in Bünde, and preparations for the next expansion have already started there – earlier than originally planned – with the third large production line going into operation in 2009. Complementary specialties such as baked-on siliconisation for sensitive biotech drugs and smart syringe accessories have further accelerated the breathtaking growth in this field. Now the Group presents an again further developed range, in which a quite different aspect takes centre stage: i.e. labelling.
As the first manufacturer in the world Gerresheimer is launching glass syringes with laser encoding, thus offering a tailor-made track-and-trace solution. The basis is a specific laser technology through which all the essential data for identification of prefillable syringes are baked into the glass so that they are identifiable right along the entire supply chain. On one square millimetre of the finger flange this process accommodates individual identity codes, for example about the nature and type of the syringe batch, providing maximum security against manipulation and visible to the naked eye only as a transparent dot.
Attractive new possibilities for labelling are additionally opened up by heat transfer printing, which Gerresheimer is also presenting for the first time at Interpack. In contrast to the monochrome screen printing which has been customary in the past, this process permits multicolour printing of syringes. The same colour types which customers previously preferred for their screen printing can be used without change. So not only can brand logos be reproduced true to the original but matrix and bar codes, calibrations and product information can be shown – clearly differentiated from each other by colour.
Complementary components, developed for maximum safety and pain-reduction in injection practice, complete the line-up of innovative solutions. Two stars of the intelligent accessory range with the abbreviations RNS/TPE and ’TELC offer significant advantages for the pharma industry and for users, which have now been documented by studies by independent market researchers. RNS/TPE stands for the Rigid Needle Shield, for which Gerresheimer has inter alia already won a WorldStar award from the World Packaging Organisation (WPO), and is a needle protection system which is impenetrable for syringe needles – consisting of a hard shell and a soft core of thermoplastic elastomer. TELC describes the Tamper Evident Luerlock Closure – a twist-open tamper-evident syringe closure, in which a needle adapter is also incorporated. In addition to these there is the Backstop, a dual-function application aid, which offers an extended finger rest and actually prevents the syringe plunger being withdrawn from the glass when the plunger rod is pulled with more than the usual force.
In the field of pharmaceutical primary packaging made of glass Gerresheimer offers a uniquely wide spectrum ranging from type-I boro¬silicate tubular glass to moulded glass of types I, II and III. The assortments of high-quality cartridges, vials and ampoules and of bottles, jars and other special containers cover practically every requirement with the widest imaginable variety of shapes, sizes and design features. It also offers a multitude of options, including not only various surface-treatment and siliconisation processes but also state-of-the-art labelling methods.
In addition, visitors to the trade fair will see a product range which perfectly fulfils current market needs. Since LOD (Large Outside Diameter) vials are enjoying increasing popularity, Gerresheimer has further expanded its high-precision SV36 technology capabilities. As a vertically integrated manufacturer the Group also internally produces the borosilicate glass tubes which are used as an intermediate product for these and countless other products, including syringes.
In the field of pharmaceutical plastic packaging Gerres¬heimer embarked on an accelerated growth path just a few years ago. In the meantime, this European business has become a global business in which the Group is already widely active as a market-leading full-service provider. The sphere of its operations in this field was substantially extended by the acquisition of two new companies at the start of the year: the leading Spani¬sh PET specialist EDP, which now operates under the name Gerresheimer Zaragoza, and the leading Brazilian pharmaceutical plastic manufacturer Allplas, which now operates under the name Gerresheimer São Paulo. Gerresheimer has thereby acquired five production locations in Southern Europe and South America and also ideally complemented its product portfolio for liquid and solid medicines. Visitors to Interpack will see convincing evidence of this.
To take just the example of closures, the range of possible variations is remarkable. Often multifunctional, with tamper-evident and child-proof design or other features, they play a decisive role in the quality and convenience of packaging. In the case of high-quality tablet containers for example, integrated desiccant mean that they also provide active protection against atmospheric humidity. In this field, Gerresheimer Vaerloese has set a completely new safety standard which already caused a stir last year, and is likely to attract considerable attention at Interpack. As the first manufacturer anywhere in the world, it established its own high-tech production facilities for desiccant capsules in parallel with its closure production. Outsourcing, which was the worldwide standard in the past, is now outdated. For this innovation as well, Gerresheimer was honoured by the WorldStar award of the WPO. There is certainly no doubt that complete production under one roof has many advantages. One of these is simplification of the licensing procedure for the pharma industry since, for safety reasons, all outsourced components of any pharmaceutical packaging must be separately registered.
As a full-service partner for medical plastic systems Gerresheimer Wilden collaborates in particular with the pharma industry and also with major companies in the field of diagnostics and medical technology – exclusively in individual project business. This business develops and realises customer-specific subassemblies across all steps in the value-added chain: from system development through to production of customised tools and special machines for production, and from injection moulding through to assembly, finishing, packaging and international logistics. Its extremely diversified product range comprises complex drug-delivery systems such as quick tests for laboratories, clinics and doctors practices, as well as a wide variety of disposables including invasive disposables.
As an up-to-the-minute innovation by Schreiner MediPharm, Gerresheimer Wilden presents the Needle Trap, an effective needle protection element for pharmaceutical syringes, which has just recently been developed. In perfect mutually complementary collaboration with this customer, which specialises in function labels with specific additional benefits for the pharmaceutical industry, a completely new type of protection against injury through used and possibly blood-contaminated syringe needles was brought to the market.
The latest developments in the field of inhalation are also featured. This is a particular area of focus for the special competence of Gerresheimer Wilden, which is becoming more and more important because of the general increase in respiratory diseases. For their treatment the company covers the complete spectrum of targeted delivery forms, with powder and capsule inhalers, nebulisers, and rhinological spray systems.
Gerresheimer also enjoys a reputation as a leading specialist in the increasingly important field of diabetes – so far primarily with patient-oriented skin-prick aids and lancets. A highly regarded example of this is the Accu-Chek Multiclix, a lancet magazine with a skin-prick aid, This was realised by Gerresheimer for Roche Diagnostics and last year won the internationally coveted TT award of the German Association for Technical Plastic Products (TecPart).
Another very interesting development area has however now opened up in the field of diabetes. This is likely to be of particular interest to visitors to the fair as an ideal example of synergy between Gerresheimers glass and plastic expertise. Pen systems for insulin injections can now be supplied by the Group from a single source: targeted investment in appropriate manufacturing technologies has provided a concrete basis for combination of specific glass cartridges and tailor-made plastic mechanisms.
Gerresheimer is currently substantially expanding the facilities of its greatest worldwide innovator in the sector of medical plastic systems, the production centre in Pfreimd in Southern Germany. In the current year alone, 2,000 square metres of additional clean-room space in accordance with ISO class 8 (100.000), are being created. Further planned expansion stages will increase the overall production area to more than 14,000 square metres by 2010 – more than 60% of which will be for clean-room facilities. This high-calibre Gerresheimer operator also has substantial clean-room capacity at its disposal in the USA, China and the Czech Republic.
For its international clientele, Gerresheimer Wilden has other good news. The production centre in Pfreimd was, in collaboration with Roche Diagnostics, recently accredited as an overseas manufacturer of medical products for the Japanese market. This means that customers will in future find it easier to market in Japan the systems and components produced in Pfreimd. In addition, the plant now has extended filling permission for clinical test samples. Previously it had permission to produce powder mixtures and fill, pack and label appropriate drug-delivery systems. From 2007 onwards, applicators can also be equipped with solid-matter implants and packed here by Gerresheimer.
Gerresheimer for cosmetics and specialties:
An extremely alluring business
Creative glass design sparkles in its own part of the exhibition stand in extremely vivacious contrast. For the international perfumery and cosmetics industry Gerresheimer is regarded as one of the most highly-qualified and multifaceted partners in marketing through glass packaging. With ingenious flacons, pots and miniatures this specialty area attracts all the product categories with a high awareness of beauty and the latest trends. For this it has at its disposal tailor-made technologies to realise every conceivable design idea in terms of shape, colour and finish.
At Interpack a breathtaking range is presented: from the classic accessory for men in black lacquer and chrome brilliance (Giorgio Armani / ‘Attitude’) to the clear glass relief flacon in a casual zip bag (Diesel/Fuel For Life). Sporty energy is for example exuded by the glass adidas woman team of flacons through its dynamic introverted shape and coated base, which creates colour diffusions in the clear glass while at the same time the brand logo provides a refreshing keynote. An equally refreshing and inimitable note is struck by Gin Tonic Fragrances for the same fashion chain, which presents its trademark fragrance in the authentic style of a long-drink glass – with a printed content line and the spray tube as a drinking straw. There can be no doubt that, in the richly stocked Gerresheimer display cases, many of the exhibits have international trendsetter potential.
The same applies for those to whom Gerresheimer devotes a small but lovingly designed sideshow on its exhibition stand for the food and beverage industry. Here trade visitors with ambitious plans will find unusual inspiration for marketing through glass design.