pims feb. 2016 packaging innovation

16 February 2016 © iDi Pac Ltd 2016

Confidential

Innovation in Pharma Packaging to Drive Business Growth

Prepared for: PIMS Berlin 2016

Ideas | Development | Implementation © iDi Pac Ltd 2016

Confidential

16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm iDi Pac - Who we are and what we do?

iDi Pac is a Packaging and Supply Chain Consultancy. Working at the interface of Packaging Technology and the Supply Chain we provide innovative thinking required to implement a truly End to End service; ideas through to Development and implementation. We excel in understanding the challenges of our clients and their stakeholders with the technical expertise, experience & imagination to develop optimised Packaging Technology & Supply Chain solutions.


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm iDi Pac - Expertise and Proposition

…our philosophy

…delivering value at this STRATEGIC

overlap


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm

Patient Adherence •  Better communications •  DigiLeaflet Technologies •  Discreet and travel packs •  Personalised medicines

Smaller Batches; how to manage effectively •  Late stage customisation •  Manufacturing flexibility •  Portfolio management •  Rapid changeovers •  3D printing of components

Trends we will be reviewing and how Packaging Innovation can support in addressing these issues

Traceability •  Unit doses in hospitals •  Component tech example

Future Concepts •  Printed electronics •  Printed drugs •  Augmented reality •  Holographics •  Flexible screens


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16 February 2016


50% of patients do not take medicines as prescribed & miss doses Wasted medicines cost NHS in England around £300 million per year. Academy of Medical Sciences 2014

$188 billion lost annually to US pharma industry due to medication non-adherence. Capgemini 2012

125000 deaths annually due to non-adherence How can communications be improved for greater adherence? What innovations can drive adherence?

Patient non-adherence: The costs


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Existing packaging communications

Seniors (and others!) already have issues with current packaging systems: Readability of text – small font sizes Overwhelming presentation of information Oversized PILs Black & White presentation


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Macro trend … short lead time, smaller batches, more data!


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Delivering for today’s market demands - DigiLeaflets

Conventional

Sheet

Trim

Bind

Cut

Fold

Collate

Print

Booklet

Roll

Complex

Pre-Print OR

DigiLeaflet

Print Fold-Cut-Form-Seal-Trim

Booklet Material Load

In-line Print-Fold-Cut-Form-Seal-Trim Booklet Material Load

Simple


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Performance data Vs existing technology

Reduce processes, reduce labour, reduce capital…….cost effective booklet formats

Effect of Changeover Time vs Absolute Output

Change-over times become ever more critical as batch sizes fall


Confidential

16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Discreet use & transit packaging

Why broadcast that you or your loved ones are taking medication? Do wish that others know? Opportunities for pocket-friendly, travel-friendly disguised, discreet packaging and medical device designs to encourage adherence in ‘real-life’ situations Encourages use in situations where privacy is limited. Reduces stress for the user & discomfort for others


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Engagement: Brand adoption

Use design to remove stigma & mask underlying functionality of delivery system Penetrate markets/increase sales by leveraging goodwill generated by user-friendly packs


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Made ‘just for you’ - Personalisation!

Creates emotional connection to encourage repeat use & generates goodwill for product/brand Requires manufacturing agility to deliver..! ..and new technologies e.g. Print on Demand


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16 February 2016


Portfolio management Standardisation Flexible, agile manufacture Novel application of technologies ‘New eyes’ to review pack systems

Core activities to be addressed

Segmentation & use in the market Understanding of market place/user practices


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16 February 2016


Existing manufacturing strategies typically aligned to mass manufacture of key SKUs/few change-overs. Pressure to adapt to changing demands… For example: Breast Cancer treatment, identified as 10 x strains, ergo there are 10 x treatments, now ten times number of batches at smaller sizes Supply chain has to deliver more SKU’s at lower volumes, more frequently – cost effectively …on lines that are designed for quite the opposite

Small Batches: The trends


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Late Stage Customisation: Print on line

Market specific text on label (digital)

Common Core pack

Market specific leaflet

Sequentially numbered label (digital)

Datamatrix code for core pack, label and leaflet

Tamper evident feature


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Manufacturing flexibility

Challenge: Reduce complexity and increase manufacturing agility. Identify all components and their interconnected relationships – physical and graphical, markets, user patterns, geography… Review all market data & supply chain requirements Have a vision of ideal solution (JIT manufacture? Print online? Universal secondary packs? Coding/traceability? Electronic artwork creation/approval?)


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16 February 2016


Portfolio management of small batch programme: Typical outcomes

Component reductions > Increase in line capacity Contract pack volume moved in-house > Product security improved Extended product life cycle > Increased orders Product lead-time = super responsive > Short payback payback on capital spend Increased segmentation > Extended sales Exploiting Print on Demand technology:

Lead times for packaging - effectively zero Scrap – effectively zero Significant storage reduction Full serialisation/anti-counterfeit capability


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm 3D printing for customised applications

The new Proposal on Medical Device Regulation increases standards for non custom-made 3D printed medical devices by introducing stricter identification, traceability and registration requirements IP issues for organs/implants? Who owns data?


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Late stage customisation: Benefits in summary

•  Needs to be part of a business strategy – not just a tactic

•  More efficient pan-continental / global supply sites by

supporting local markets

•  Can offer more variety – access to medicines for emerging

markets

•  Allows for more frequent deliveries, lower volume order size

•  Offers local language packs / more SKUs – more sales!

•  Agility in the Supply Chain


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Traceability: Regain control of your property


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Serialisation: Clock is ticking


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16 February 2016


Medication errors & human cost (One in 10 patients harmed)– preventable! ‘Pharmacovigilance’ – World Health Organisation -Pack labelling/identification raised as issue Vulnerability to counterfeiting -Cost to industry in lost revenue estimated between $75-200billion (WHO) What’s your strategy to combat these issues?

Traceability to unit dose level

500 Dead: Glycol

Counterfeit inhaler: Bacteria in lungs


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16 February 2016


Reduce opportunity for error: - e-prescription - Confirmation at dispensing - Identification on ward - Correct administration …confidence in the system! Through trust create sales and improved outcomes - supported by insurers

Traceability: Unit doses


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16 February 2016


The container, called ‘Barrel’ is sized from 0.2-5mL ‘..the advantage of separating the container and it’s application system is that filling and assembly can occur at different places – thus the delivery chain remains flexible..’ Sulzer Mixpac Key to success is successful strategy of traceability/ serialisation for drug & componentry - with the opportunity of personalisation

Unit dose technology


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16 February 2016


Opportunities through innovation to enable greater patient adherence via awareness, communications and delivery

Future ideas


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Printed electronics...further help for adherence?

Increased lifespan in development.. with solar panels (battery life an issue..) Intended use functional rather than FMCG gimmick Early adopters in Pharma could exploit full possibilities! (does not impact recycling stream – yet)


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm 3D printing of medication

‘In future, the mechanism of treatment will be inverted, with clinician feeding the diagnosis and treatment requirements to a manufacturing suite, who will dial up the materials required and the structure needed to deliver the perfect treatment profile - ready to printed locally and near to point of care. Through the combined efforts of science, industry and regulatory authorities we will see this realised in our lifetime’ Prof Ricky Wildman, University of Nottingham


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16 February 2016


Barriers: High temperature of printing process Compatibility of drugs Limited to niche applications ..compliance with regulations! Benefits: Tailored to individual’s needs Dosage specific Constructed to performance spec

3D printing


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Augmented reality

FMCG brands use for fun & promotion Opportunity for pharma industry to adopt the right ‘tone of voice’ and encourage engagement and connection with products/brands Use as instructional, motivational & educational tool to ensure correct usage of product Choose the correct audience – medium is the message


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Broadcast holographics

Launched this January in Japan for Nestle Kit Kat Works via youtube clip and flat piece of clear plastic folded into a pyramid.


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Internet of things

Image courtesy of Chragokyberneticks

Concept of enabling internet-based connection between computing devices embedded into everyday objects Opportunity to go beyond mandatory information exchange & create deeper relationship


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16 February 2016


Printable screens on flat/flexible surfaces Content tailored to patient Demonstration of administering drug - animation or moving image Content updated & broadcast to pack throughout product lifespan?

On-pack video


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16 February 2016

Client Logo (change me in master slide) Max 5cm x 2cm Thank you for your time – Any questions?

Email [email protected] Tel +44(0)1420 538055 www.idipac.com

pims feb. 2016 packaging innovation

Engineering