CurTec plastic lidded crates boost cGMP at Sanner

Case Study: Overview

Faced with new GMP and GDP standards, primary pharmaceuticals packaging manufacturer Sanner needed a better alternative to the cardboard boxes it had been using for storage and shipping of warranty closures.

The new packaging also needed to provide improved process efficiencies. CurTec’s Lidded crate offered an ideal solution and significant customer benefits.

Sanner

Sanner’s factory at Bensheim, near Frankfurt-am-Main, produces around 2 billion plastic packages and packaging components each year for the pharmaceutical industry. A large number of these are warranty closures.

Sanner’s existing process was to collect closures in large cardboard boxes following production. These boxes could be reused, but caused various drawbacks in the process.

“Every time we needed to use a cardboard box we had to unfold and tape it,” recalls Mr. Monitzer, Production Leader at Sanner.

“Furthermore, we were only able to use the boxes two or three times. However, the main reason why we began searching for an alternative form of packaging was the need to use our warehouse more efficiently. The cardboard boxes were not strong enough for stacking and this meant that they took up a lot of floor space”, Mr. Monitzer explained.

GMP compliance

An even more pressing reason for finding a more modern alternative to cardboard boxes is contained in the latest good Manufacturing Practice (GMP) and Good Distribution Practice (GDP) standards, which dictate that cardboard, cannot be reused for pharmaceutical products because of the risk of contamination of contents.

As a German-based ethical company, Sanner is highly mindful to meet cGMP standards. Therefore it began a determined search for new packaging that would be strong, user-friendly, stackable, and completely reusable and pose zero contamination risk.

Testing plastic crates

Sanner invited various companies to provide a clean, stable and easy manageable alternative to their cardboard boxes. However, as it turned out, almost none of the plastic crates proved strong enough during testing.

As Mr. Monitzer recalls: “The hinges would break or the walls would give way when we stacked them higher. CurTec’s lidded crate was the only one emerging positively from the test.”

Unique tough construction

CurTec’s crates are made from a strong and hygienic polypropylene (PP) plastic and have been intensively tested under pressure loads. They are also carefully designed to resist the wear and tear of everyday use.

Most lidded crates have hinges that protrude above the crate, meaning that when they are stacked, pressures are concentrated on the weaker hinge point. In contrast, all CurTec’s lidded crates feature a design that places the hinges flush with the upper and side surfaces, shielding them from handling, transporting and stacking stresses.

The CurTec crates also have the advantage that they can be made easily tamper proof since they are designed to accept sealing strips or sealing pins as well as barcodes for Track and Trace applications.

Test results convinced Sanner to choose the CurTec 52 litre lidded crate, which is 60 x 40 x32 cm for a footprint of 0.24m2. Sanner opting to have their crates specially produced in their company ‘house color’ gray.

Benefits in action

Sanner has now been living with its new CurTec crates for long enough to see real benefits.
Says Monitzer: “We are satisfied with both the sales contact and the product. The crates offer real value for money.

“In addition to meeting our needs on GMP and allowing high stacking, they are also more efficient in the process. Employees on the shop floor specifically ask for the lidded crates because they are so easy to handle. In contrast to cardboard boxes, which first needed to be unfolded and assembled, these crates can be used instantly.”

Packaging Scan

Issues like footprint, handling and stacking needs, together with hygiene, safety and other cGMP issues can all be identified in CurTec International’s unique Packaging Scan consulting service.

Packaging Scan is a must for any client looking to optimize its packaging in line with strategy and company objectives.

Resources

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