Adapting to Trends In Drug Delivery

Sonic Packaging combines design and manufacturing services to offer custom solutions that support compliant use.
Sonic Packaging ( is offering in-house design, engineering, and filling services to help customers develop unique packaging solutions and support trends in unit-dose medication delivery. With the launch of the company iDE (Integrated Design and Engineering), Sonic provides a domestic resource for turnkey package development and contract filling. The company builds on Sonic’s 17-year history as an ISO 9001-2008-certified global resource for packaging solutions.
The Florida-based IDE is meeting customers’ needs for distinctive delivery systems that support specific and targeted dosing, says Howard Thau, president of both Sonic Packaging and iDE.
The MV1 injection-molded ampoule for unit dose features a break-off tip that can be inverted for reclosing in multidose applications. An incorporated flow-through brush applicator suports precise dosing.
iDE’s services encompass initial design, prototyping, tooling and injection molding, compatibility and stability testing, and filling under pharma cGMP conditions. Single-use devices with controlled or metered-dose delivery systems figure prominently in iDE’s portfolio as a fast-growing category at hospitals, doctors’ offices, the retail level, and in numerous other markets, Thau says.
Customers are looking for packaging that provides barrier-to-entry, complies with requirements for safe and consistent product use, and that adds to the end-user experience, Thau says.
“The feedback we heard from big and small customers alike is they are not getting the creative solutions they need currently and will continue to need for future years to come. Our customers are also concerned about materials sourced from overseas that may or may not meet their standards,” Thau says.
Customers are not led down a pre-determined path that leads to only one solution. “We have an opportunity at iDE to design and build our customers’ packaging components from the ground up [using our] network of global suppliers for the tooling and injection molding to standards not only expected by our customers but that we adhere to in our daily practices. We can develop truly unique patented delivery systems based on their needs,” Thau says.
“The average fill volume for unit-dose packaging is 0.1 ml to 10 ml. However, iDE is able to customize dosing units for fill volumes of less than 0.1 ml,” he adds.
iDE’s initial design is the MV1 injection-molded ampoule for unit dose, which features a break-off tip that can be inverted for reclosing, allowing it to also function as a multidose application.
In the Med App device, an ampoule with a foil lid is pushed into the sleeve, where an internal piece punctures the foil. The body is squeezed between thumb and forefinger to release a dose controlled by an applicator tip selected for the application.
“The MV1 was originally designed in a 1-ml size without a specific customer in mind. As we marketed it, customers asked for a flow-through brush applicator where the brush is incorporated into the package. Through development by our on-site engineers, we are now able to offer this as an option, as well as in larger 10-ml and 15-ml sizes. We are also able to offer our other delivery systems with a variety of applicator tips other than brushes, such as swab, flocked, or coated tip,” Thau says.
iDE’s calibrated “Pick Dose” syringe addresses the over and under dosing of children’s medications. The doses are dialed in by pulling back the plunger of the syringe to the premeasured dose. For a multidose option, iDE developed the ContiDose, which is currently available in a pump system. It can be preset for up to eight fixed doses.
iDE is a 12,000-sq-ft temperature and humidity controlled facility that features three production suites, with a Class 100,000 reduced particulate environment and one Class 10,000 cleanroom. Blister packs and other secondary packaging are also developed and engineered in-house for designs that support compliance and intuitive use, Thau says.
A custom-built stick pack machine accommodates powders, with newer technology for liquids and gels, produced in laser-scored, tapered-spout designs.
“Customers will perceive the opportunity in different ways. Unit-dose formats are favored for sampling as well as trade packaging. We are now in a position to quickly adapt to their specific needs with a finished product that functions stably and consistently,” Thau says.
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