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Aerospace-derived technology helps create more insightful temperature-controlled packaging solutions

Multi-Physics technology used to develop jet engines and Formula One cars offers an alternative for pharmaceutical applications.

Simulation and virtual prototyping is becoming an important and indispensable stage in the development of robust, cost-effective temperature-controlled packaging, especially when project timeline pressures are a major factor. The packaging industry is now able to consider the use of the previously cost-prohibitive Multi-Physics (MP) technology used in the development of jet engines and Formula One cars for developing complex temperature-controlled solutions for its pharmaceutical clients.

The simulation capabilities of MP enable packaging suppliers to significantly increase the efficiency of a design process and allow for a more expansive and innovative exploration of solutions to meet customer requirements. In fact, a test using MP will take approximately one tenth of the time it would take to run a physical test in a laboratory.

MP works by creating a 3D CAD model of the temperature-controlled packaging that is to be tested, which includes the various insulating materials, the temperature stabilizing components, and the product in the shipper, with temperature variables being associated with each part.

Traditionally, when developing and testing a new temperature-controlled packaging system for a client, packaging suppliers would undertake a number of iterative Design Qualification Tests, taking into account the transit duration time and variable temperatures it would expect to see during transport, in order to configure a shipping solution in the laboratory: a process, which undertaken in real time, could take months.

For example, in real time, if a laboratory test takes five days to perform, packaging suppliers will initially have to wait five days before they know whether or not their first configuration of a system will work. By using MP, a virtual Design Qualification Test is performed. Although the results are not relied on to be 100% accurate, they give a strong indication as to whether a packaging configuration will be good enough to move it to the laboratory for the physical Design Qualification Test. So, in essence, rather than undertaking a three-month development phase in the laboratory, three weeks can be taken. That condenses the development period, which enables suppliers to fulfil a customer’s requirements sooner.

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