With the impetus and encouragement received on a national level, the packaging industry has made a steady progress over the years and has now stabilised with a reasonable CAGR.
Considerable R & D is done and this activity continues to get a prime importance to innovate new materials, new material combinations, newer developments in processes and technology with state of art communication systems.
The industry also is seized of the necessity to address the changing needs with emphasis on safety and convenience. All waste disposal and medical device packaging wastage have been specially tackled. Product dispensing and dosage form requirements have also received special attention.
The one group of packaging media that have made great inroads into virtually every product packaging application offering varying and effective advantages are the polymer/plastic based packages. Bulk drugs, pharmaceuticals and related products packaging,marketing and consumers have been considerably benefited by the commercially produced and available materials, so also the developments of packaging machinery and systems.
Recent developments related to industrial and environ issues seem to possibly negate all the efforts over the years but at the same time raises eyebrows and a number of questions, relevant or otherwise, could be the starting point of debate for pharma packaging. The industry would recall the traditional methods of packaging that were in vogue.
Notwithstanding the goodness of these packages the safety , market, storage, dispensing and various other demands have directed the pharma and packaging industry move together vigorously and achieve tangible results which could help identify solutions for the concerns and causes. Polymer/plastics based materials were in the forefront and because of their versatility and forms available besides in terms of flexibles, the permutations and combinations possible, have become an obvious choice.
The national regulations being announced one after the other possibly bringing every efforts and successful adoption of many packaging even for sensitive pharma products, raise a number of debatable points. It is easy to raise a slogan of “Ban” but difficult to provide an answer leave alone to justify “Why Ban?”
In pharma and drugs it is not just prevent diseases or cure diseases but significantly” save the life”. Packaging has already been under the “lens” of cost control and hence there is no luxury. It is just to ensure to maintain the potency and conform to the shelf life.
The subject of “Ban” should also address materials availability, their storage and handling, inventory carrying cost, production line amenability and productivity, transportation cost, retailer capacity for inventory quantity and dispensing to consume/consumer convenience.
The retail pack quantity and /or number is influenced by the patient’s illness and prescription of the doctor. Evolutions in packaging have been and probably continue to be based on the above. It is equally known that the R & D and physiological and biological oriented R & D be it the product or package is much more stringent in pharma sector. Every material and constituents in the package are as prescribed norms and considered harmless to the human system. They also conform to the published standards and norms.
Analysis of a few examples would reveal the process ,the needs and benefits.
Tablets and capsules were traditionally packed in glass bottles.Depending on the doctor’s prescription the retailer/chemists either would give a full bottle or the required numbers counted and sold to the customer. In the process (for OTC products) the tablets/capsules are poured over the counter table, the requisite number counted and given to the customer. The remaining tablets/capsules were returned to the glass bottle. One could imagine the multiple handling, exposure to atmospheric conditions, higher possibility of contamination. The same situation continues at the patient’s end. The first shift was seen towards HDPE bottles. The disadvantages remain the same except lighter weight and no fragility. The extension to secondary packaging would give added benefits from HDPE bottle over glass that would need better and additional cushion.
The evolution then was to strip packaging followed by blister packaging. Individual tablet/capsule protection, considerably reduced atmospheric pollution, customer convenience , ease in carrying and dispensing. But virtually all constituents of the pack is plastics based. Is Ban on plastics/laminates would help and salvage!!. One should also integrate backward the production cost of a bottle vs the strip and blister and the minimum order quantity. Both strip and blister facilitates direct printing –but glass does not (If yes- cost, then who will pay?)
Cough syrup is yet another example. The shift has been towards PET bottle that could be produced in two stages. Whereas a master plant could produce preforms and distribute to various locations the other is a single stage bottle production. The former becomes cost effective, unbreakable and could suit small scale/medium scale moulding. Secondary and tertiary packaging needs are cost effective. Standardisation of neck finishes enable cap standardisation and packaging line machines and operations.
Vials today are transported as palletised load with shrink or stretch wrapping which makes the pallet load tight and aids effective unit load devicing. Should we do away with the unitisation programme and go back to CFB box packaging with overall added cost. Can “Ban Plastics” slogan give an alternate.
Multidose injection vials were not far back with glass syringe and needles. Multiuse carried with them the avoidable problems. Enters the single application plastic syringes with needles. Disposable plastic based system has ensured safety and avoid adulteration. Is development a “Crime” ?.
The progress in medical devices packaging has been augmented by and through determined R & D and developments in synthetic materials. The hospital waste disposal system is well defined. Should also these plastics be sidelined. If yes, one has to recommend useable, functionally suitable and cost effective alternative.
Over the years electral powder is an essential remedial product for children suffering from dehydration. The package is a multilayer structure providing excellent barrier to all deteriorative atmospheric elements and ensuring desired shelf life. What could be the alternative? A paper based cup; an aluminium tray and lid; alu.tube or a glass bottle. Is there a scope for debate or just leave the product and market to decide- what is best for them
IV solutions- originally available in glass has virtually switched to plastics. Could the reasons be revisited and if justifiable to glass. So also the feeding bottles for children. Over the years the glass has been replaced by polycarbonates/polypropylene. Sterlisability of the alternates is well established. Should the industry go back to bottles? Could a comparative evaluation done to establish the merits and demerits?
A large number of malted foods , energy foods and childrens’ foods have their packaging shifted to bag-in-box or lined cartons. A study should help as to why one is preferred over the other. If the consumer preference is towards the “Package type-shifted” could the “Ban the use of Plastics” review?
While the above or a few examples cited for a review towards the biasness to one or other material (s), what the industry with the active support, participation and involvement of the government and central and state government agencies, the plastic industry and package users should converge , discuss and draw up a well defined action plan and network towards to set goals to reduce possible negative impact that such materials could cause. This cannot be a mere institutional approach but a collective responsibility. Let personal prejudices do not dictate the situation but create a “Come and work together culture” for an acceptable , harmless and productive answer. If one starts with the theme that “XYZ” pollutes and they are harmful to the society- then any approach already seen with the jaundiced eye will find difficult for any efforts to pursue. The task would indeed be enormous but fruitless if not wholeheartedly and positively approached.
(The author is secretary general, Institute of Packaging Machinery Manufacturers of India (IPMMI) and Chief Executive of IFCA )