A customer enlisted Catalent to support their child-resistant blister packaging requirements for a global Phase III study. A flexible design was created with an integrated blister card that could also support larger study requirements of 1.9 million monthly dosing cards. Through customized commercial blistering equipment a solution was provided that would accommodate the customer’s growing demands for clinical supplies.
Using 3D rapid prototyping, Catalent worked directly with the customer to quickly vet multiple physical designs as clinical requirements shifted while accommodating varying dosing regimens and sizes of investigative and comparator products in uniform packaging. Through ongoing collaboration with the customer, Catalent created an integrated blister card design which virtually eliminated the need for conventional wallets. This novel approach saved the customer an estimated $1 million in material, labor and ancillary storage costs.