Hi, Casey Flanagan here, associate editor with PMMI Media Group. I'm here with healthcare packaging editor-in-chief, Liz Cuneo, and we’ll be discussing the pharmaceutical innovations report that came out of last year’s PACK EXPO.
We’ll dive into the latest trends she saw at the show. Be sure to download this report at healthcarepackaging.com if you want to check out the videos and photos directly from the show floor.
Casey: Liz, I know that even the last time I was at PACK EXPO I saw some pharmaceutical innovations and really interesting things. I’m excited to get into this.
Liz: Absolutely. We’ve had some time to reflect since PACK EXPO International last fall, and now we have this great pharmaceutical innovations report to capture all the highlights.
Casey: What are some of the main trends you saw in the pharmaceutical machinery space?
Liz: Pharmaceutical packaging plays a critical role in maintaining drug stability, safety, and patient adherence, while meeting strict regulatory requirements. Today’s machines are addressing these issues while also focusing on high speeds, accuracy, flexibility, sustainability, small footprints, and seamless integration.
Casey: And how do these machines aid in drug stability and safety?
Liz: In the blister space, many machines promoted serialization capability, especially for inkjet printing on blisters. This includes printing high-quality codes, barcodes, dates, and other serialization info. Digital printers were also prevalent, with built-in inspection equipment to ensure the right codes were printed each time.
In bottling, vision-based counting stood out. One innovation was a high-speed counter that counts tablets in bulk and can detect foreign colors. Check-weighing was also common, ensuring accurate fill levels with 100% in-process control, which is vital for meeting regulations.
Casey: Sounds like there’s a wide range of solutions. What about for vials and injectors?
Liz: I’m glad you asked. Auto-injectors are a huge area right now. Products like GLP-1s (Ozempic, for example) have really driven growth, but it’s not just weight loss. The rise in biologics and chronic diseases has fueled demand for prefilled and disposable auto-injectors. They improve usability and reduce contamination risks. At PACK EXPO, there were many innovations in filling and labeling equipment for auto-injectors.
Casey: What stood out to you in that space?
Liz: Labeling challenges. Auto-injectors have unique shapes and plungers. If a label is applied with too much force, it can activate the plunger and waste the medicine, which is costly. A new solution showcased controlled labeling force using a device stabilizer to prevent that problem.
Casey: That’s interesting. Did you see other labeling innovations?
Liz: Yes. For glass products like vials, precise and gentle labeling is key, but machines also need high speeds. Serialization and aggregation were major themes. Aggregation links individual units like bottles or blister packs to higher packaging levels — cartons, cases, pallets — ensuring complete traceability. Robotic labeling was also highlighted for small batch, high-mix, low-volume needs.
Casey: Let’s talk flexibility. Why is it so important in pharmaceutical equipment?
Liz: Flexibility is essential across industries. Many OEMs now highlight machines that can handle liquids, tablets, powders, gummies, and more — while still filling with 100% accuracy. One rotary filler could handle gummies in containers made of glass, metal, paperboard, or plastic. Machines also need to allow quick changeovers and small-batch production, especially for clinical trials.
Casey: You can’t talk about pharma packaging without cold chain. What trends did you see there?
Liz: Sustainability was the main focus. We saw recyclable and compostable films, cold packs, and a big move toward paper mailers and pouches instead of plastic. Many were curbside recyclable, making it easy for end users to dispose of responsibly.
Casey: Sustainability always seems to be a factor. Did you notice other highlights there?
Liz: Yes. One blister machine had system changes to better handle the inconsistencies in sustainable materials. There was also a mono-material glue-free carton designed for products like eye drops, giving manufacturers a more sustainable carton option. Across personal care, med device, and pharmaceutical industries, many packages were curbside recyclable or lightweighted to reduce material use.
Casey: Sounds like there was a lot of exciting innovation at PACK EXPO.
Liz: Definitely. These innovation reports really highlight everything we saw, and there’s even more coming this year at PACK EXPO Las Vegas starting September 29th. Be sure to check out the show and download the updated reports we’ll be creating after the event.
