Ruspak Gains Clients With Flexible Response and Cost Control

Ruspak ( has captured business with a quick response focus on customers’ packaging requirements and shipment timelines. For blister packaging of OTCs for a Polish distributor, the Lyons, NY-based contract packager recently added an EU-certified clean room with a blister line producing “soldier packs” for shipment abroad.
“Outstanding customer service is our priority. As the last one in line in the product development cycle, we have to be ready to jump through hoops for the customer,” says Tim Brickle, Ruspak’s president. “We always have two shifts running, and when its called for we move to three shifts for around the clock production.”.
Ruspak stepped in with a solution for a Canadian company with a whey protein mix after the manufacturer encountered a score of cGMP issues with its previous contract packager and ran out of product. In a three year contract, the packager established a dedicated packaging suite in two weeks with a Bartelt horizontal form-fill-seal pouching machine. A second line was added within a month.
For pouch packaging of caffeinated peppermints for meals-ready-to-eat (MREs) for the U.S. Military “we designed built and debugged the line in a week for approval as a supplier,” Brickle says.
Ruspak built a Class 100,000 clean room with an $80,000 investment for the blister packaging of laxatives and antacids distributed by the Polish customer. The facility includes a Klöckner CP10 blister machine, rebuilt by Pharmaworks, a gowning area, and a HEPA (high efficiency particulate air) filtration system for filtering down to micron size.
Blister tablets are inspected with a Banner PresensePlus P4Area camera with seven-inch monitor and back light. Components were provided off the shelf by K.O.M. Lamb.Tablets are rejected if a quarter or more of a tablet is missing.
“This is a $40,000 system that we developed for $3,400 by working closely with our local supplier. On our blister and labeling lines, we are moving to character recognition for the printed lot and expiry data within a year,” Brickle says.
Ruspak runs two IWKA Model TFS10 tube filling machines for packaging petroleum jellies for medical applications, vitamins, and cosmetic products, in tubes of 0.5 oz to 12 oz.
Brickle says Ruspak’s customers are often looking for a one-stop solution, though others will source materials for example to keep costs in check. The in-house engineering staff works with local machine shops to design blister and pouch filling machine tooling. “Local machines shops make the majority of our tooling, often at a price that is one third or one half of what the machine manufacturer would charge,” he concludes.
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