A world-leading pharmaceutical maker needed to quickly bring production of a delicate medication in-house, so they turned to MGS and our Coesia sister company, Enflex, for a customized solution—read on to learn about the unique two-phase, integrated approach.   

A breakthrough medication meets a growing challenge 

When a pharmaceutical giant brought a revolutionary new treatment to market, they faced an unexpected problem: how to meet the unprecedented surge in demand without compromising quality. 

As developers of a life-saving powdered medicine used to treat severe electrolyte imbalances, this renowned pharma manufacturer was well aware of the importance of high-quality packaging to deliver their groundbreaking product.  

Originally, it worked to outsource production of this pouched medication to two different suppliers. But, as the success of the product grew, so did demand. The suppliers struggled to match the pace, and the pharma company knew they needed to take control of their production, and they needed to do it fast.  

However, bringing production in-house brought its own challenges. The medication's chemical makeup was extremely hydrophilic, making filling the doses highly sensitive, meaning any amount of moisture in the production process would alter the stability of the powder. They needed pharma-compliant equipment that could dose their product with fine precision into flat, airtight pouches with enough speed to meet booming demand for the life changing drug. 

Why they chose MGS 

Here at MGS, we’re well known for complex integration tailored to the toughest challenges and stringent regulations of the pharmaceutical industry. With an extensive portfolio of sanitary, cGMP and GAMP compliant systems, we offer custom packaging and product handling equipment trusted by health care manufacturers worldwide. 

And as a Coesia company, we have partners worldwide in the entire Coesia Group of industry-leading packaging companies. One such company is Enflex, a Volpak brand, and a manufacturer of high-performance pouching equipment.  

We collaborated closely with both the pharmaceutical company and Enflex to design a unique two-phase approach that would both bring production in-house as soon as possible and present a future-ready plan for a fully integrated, high-speed packaging line. 

Phase One: obtaining rapid in-house production 

Phase one centered on helping the company quickly get control of their own production. The top priority was providing them with reliable, pharma-compliant equipment that had both a proven reputation and a short lead time. 

We began by exploring Enflex’s portfolio of solutions. After determining the best way forward, Enflex immediately began working on building and installing one of their standard pouching machines so they could quickly begin filling their products in-house with reliability and precision. 

This alone reduced outsourcing costs and accelerated production as they prepared for a longer-term, higher-volume solution that we collaboratively designed specifically for them. 

Phase Two: scalable production for the long-haul 

Phase Two focused on future-proofing production with a complete line custom-made for the product that could further increase output. This included a switch to a more customized, higher-speed Enflex machine to increase pouching throughput while maintaining precise dosing. 

But there was more to this product than pouching; integration with high-speed, flexible product handling and secondary packaging systems were crucial to meeting demands. So, we at MGS designed a completely custom product handling module from the ground up. This tailored solution gently batched the filled pouches into flexible counts and configurations. The pouches were then ready to be loaded into our industry-proven Eclipse CT, a servo-driven intermittent motion cartoner known for its accuracy, speed, and rapid changeover capabilities. 

Each piece of machinery was equipped with Coesia Digital Optimate HMI for reliability and easy access to things like machine controls, guided procedures and real-time performance analytics. For added assurance, we also integrated a checkweigher from an external OEM partner to create a closed-loop system for dosing corrections. This verified the fill weights of the pouches and sent data directly to the Enflex machine, ensuring every pouch met strict dosing specifications. 

A seamless solution that more than delivered 

The result was a seamlessly integrated, all-encompassing packaging line that delivered precision, flexibility, and scalability, all while meeting strict industry standards and exceeding expectations. 

The company not only achieved immediate control of their operation, but saw improved efficiency so effective that they ordered three additional machines to further expand the production of this essential medication. 

By tapping into the expertise of MGS and our sister company, the pharmaceutical giant found unmatched expertise in handling complex pharmaceutical projects thanks to our custom integration experience, array of packaging technologies, and commitment to solving our customers’ toughest challenges. 

The benefits of Coesia integration 

This success story highlights a key advantage of working with MGS: our international network of similarly innovative Coesia companies like Enflex. Whether you need a single solution, custom robotic, or fully integrated line, MGS together with Coesia will have you covered with our unparalleled range of packaging, handling, and ancillary capabilities.  

For other pharmaceutical manufacturers facing the challenges of growth, regulation, and product complexity, MGS and our sister companies provide a proven path forward with trusted solutions and integration capabilities.  

Have a complex pharmaceutical packaging need? Reach out to MGS today to see how our innovation can expand your possibilities and exceed your expectations.