Background
A global pharmaceutical leader, required a specialized packaging solution for storing high volumes of vials and bottles in cold storage environments. The company’s traditional paperboard packaging posed a challenge in damp, refrigerated conditions, as it absorbed moisture and was prone to developing mold. This exposure to moisture also weakened the packaging’s structural integrity, putting fragile products at risk.
With over 40 years of experience in custom design and contract packaging, Deluxe Packaging was selected to engineer a better alternative. Merck needed a partner capable of delivering a high-volume, mold-resistant, and cost-effective packaging system that met its stringent cold-chain requirements.
The Challenge
The primary challenge was the degradation of paperboard packaging in cold storage, which created a contamination risk for sensitive pharmaceutical products. The partner required a new packaging system that would not only remain hygienic but also integrate seamlessly into its existing logistics.
The new packaging needed to meet several key criteria:
- Moisture and Mold Resistance. The system had to prevent mold and moisture absorption to ensure a hygienic storage environment.
- Compatibility. The packaging was required to fit into existing cold-chain shipping containers.
- Versatility. The solution needed to accommodate multiple vial and bottle sizes for various products.
- Scalability. Production had to be scalable to tens of thousands of units annually to meet high-volume demand.
- Efficiency. It was vital that the packaging system enabled clean and efficient storage and transport for facilities in the U.S. and Europe.
The Solution
Deluxe Packaging designed and delivered a comprehensive packaging program customized to their operational and regulatory needs. The solution included expert material selection, custom container engineering, and multi-location fulfillment.
Material Selection & Design
After careful consideration of performance requirements, we proposed a plastic corrugated storage container in place of the mold-prone paperboard. Our team reviewed multiple types of corrugated plastic to determine which option would provide the ideal combination of durability, rigidity, and weight.
Corrugated plastic offers the ideal properties for humid and refrigerated environments; it is lightweight, water-resistant, and durable. Our corrugated plastic is made from BPA-free polypropylene, which is non-toxic and safe for pharmaceutical applications. Additionally, this durable, reusable material would allow our client to reduce packaging expenses and lower their carbon footprint.
Custom Container Engineering
Our engineering team custom-designed plastic corrugated boxes, trays, and partitions to house drug vials and bottles of various sizes. They developed drawings for everything from narrow, single-vial compartments to larger partitioned trays for bulk handling, after which the die maker produced samples for testing and approval. We opted for die cutting because of its ability to produce highly precise and scalable packaging, meeting the client’s high-volume requirements.
Multi-Location Delivery & Fulfillment
After our new product designs were approved by the customer, we manufactured tens of thousands of units and packed them for delivery in our state-of-the-art facility.
The packaging was delivered on a just-in-time basis to our partners U.S. and European facilities. This on-demand fulfillment supported variable demand while minimizing on-site inventory for the client. Deluxe Packaging managed the component sourcing, assembly, warehousing, and distribution to ensure timely and consistent delivery across all locations.
Secondary Services Included:
- Design engineering
- Assembly
- Component sourcing
- Warehousing
- Distribution
- Supply chain management
- Drop shipping
The Result
The switch from paperboard to plastic corrugated packaging significantly improved our partners cold storage operations and resolved its contamination concerns. The solution delivered the following results:
- Mold Prevention. The plastic corrugated materials eliminated the risk of microbial growth, even in high-humidity storage areas.
- Packaging Longevity. Unlike paperboard, the durable plastic containers maintained their structure and integrity over time.
- High-Volume Scalability. Deluxe Packaging successfully fulfilled tens of thousands of units per year on demand, ensuring a continuous supply without overstocking.
- Cross-Location Consistency. All packaging solutions met their cold chain specifications and fit seamlessly into existing shipping containers at its global locations.
- Stronger Vendor Relationship. The project solved a critical challenge and established Deluxe Packaging as a trusted supplier, creating opportunities for future packaging initiatives.
Partner with Deluxe Packaging for Your Cold Storage Needs
Deluxe Packaging’s work highlights its value as a strategic packaging partner in the pharmaceutical sector. The project demonstrated how intelligent material selection and custom engineering can solve critical challenges like mold in cold storage without disrupting supply chain operations. With a full-service offering that spans design, production, and logistics, Deluxe Packaging helps companies meet complex operational and regulatory requirements through innovative and scalable solutions.
If your business is facing cold storage, moisture control, or packaging compliance issues, Deluxe Packaging has the tools, materials, and expertise to deliver a tailored solution.
Contact us today to learn more about our custom packaging capabilities.