Allergy Relief Now Available in Swabs

Zicam�s Allergy Relief is now available in single-use swabs.

The new Allergy Relief GelSwabs are the latest in a line of product introductions using the patented GelSwab delivery system. The GelSwab was first introduced on Zicam Cold Remedy, which represents the majority of the Matrixx business. “The swabs are easy to use and hold more of a sanitary appeal for consumers,” explains Albert Hwang, Zicam’s brand manager. “Although the gel spray is very popular, many consumers prefer the GelSwabs because of their ease of use, portability, and premeasured single-dosing swabs.” The popularity of the GelSwab delivery system motivated Matrixx to apply the technology to its Allergy Relief and new Cold Sore product launches. Puritan Medical Products Company LLC (Guilford, ME) provides the swabs.

Originally in a flexible package, the gel-saturated swabs were reintroduced to consumers in rigid tubes in November 2006. The tubes were modeled after an existing delivery system that was used by Matrixx prior to an acquisition.

The Tech Group (Scottsdale, AZ) helped Matrixx modify the original design for injection molding. The company then sourced the polymer and supervised the injection molding process.

The Tech Group worked with several equipment suppliers to build Matrixx's swab filling and packaging line.

The Tech Group was also responsible for managing the design and manufacture of the tube filling, sealing, and labeling line. Various equipment builders collaborated on the project. According to Matrixx, the production line scores and labels the tubes, inserts the swabs and fills the gel, and then seals the tubes. The tubes are then inserted into an erected 20-count carton along with an insert, sealed, lot and date coded, shrink-wrapped into bundles of six units, and placed into shipping cartons.

Given the tube’s narrow body, keeping the label straight and completely wrapped around the tube after application was a bit of a challenge. Labels are supplied in 18-in. rolls using a PET carrier, Matrixx explains. As the labels are fed through a series of rollers, they are removed from the carrier and applied onto the tube. Matrixx had to identify the proper amount of adhesive that would allow for easy removal from the carrier yet apply easily to the tube without curling. Custom Label (Hayward, CA) provides the labels.

Cold Remedy and now Allergy Relief will remain available in both spray and swab versions, says Hwang. Consumer preference is almost evenly divided, with a growing preference for the GelSwab delivery system, he explains. “Consumers drive everything,” he says. “We have determined that more than 90% of Zicam users come back because our products work. Our clinical research on Cold Remedy has shown that users get over colds three times faster when product is applied nasally. Word-of-mouth marketing is a key strategy for the brand, and we feel that our innovative delivery systems help drive that. So we are interested in continuing to invest in delivery systems that help consumers get better faster.”