PharmaPac is a Contract Manufacturing Organisation (CMO) that focuses on the manufacture and packaging of a variety of drug delivery systems to the highest quality standards. The company was incorporated in 1996 by three directors who previously worked together at Bristol Myers Squibb, and who were later joined by other ex-colleagues, some of whom are still working at PharmaPac today.
Over the years, the company has expanded significantly to become a significant turnkey solution provider to support the unique requirements for some of the world’s largest pharmaceutical, consumer healthcare and veterinary companies. At the company’s purpose-built facility, solids, semi-solids, liquids, and powders are filled into a diverse range of packaging using state-of-the-art machinery.
Managing Director Gareth Lewis describes the core business: “We have significant experience gained in bringing products to market in the pharmaceutical, consumer healthcare, veterinary and nutraceutical industries, which we can use to help customers design manufacturing, filling and packing processes. We can create custom manufacturing and filling lines, identify, source and validate new processes and equipment for a whole range of new projects.”
He further affirms that PharmaPac’s reputation for excellent service and exemplary quality standards has enabled the company to win new contracts and retain existing business with significant global companies. “Some of these relationships have been in place for over 20 years. And new customers who see our facility and meet our people can feel confident that their brand is safe at PharmaPac, and that their product will be available to patients and consumers at the right time and the right cost.”
Continued investment
With a broad range of equipment, PharmaPac can meet the needs of any customer and offer a fast, efficient, and cost-effective solution for their packaging needs. For customers designing novel medical products using alternative liquids, solids, semi-solids, and powders PharmaPac can help create pioneering packing lines given its extensive experience. 
A recent example has been the introduction of serialisation to its lines, following government directives to prevent falsified medicines or counterfeit drugs. By individually printing each carton, followed by a verification check, a unique 2D code, each consumer unit creates an individual pack, thereby creating an end-to-end Track and Trace process which enables awareness of the physical location of a particular product within a supply chain at any point in time. It also allows recording of historical data regarding product movement and time spent at each stage, as well as packaging information.
The company has always invested in expanding its portfolio, says Lewis. “In 2021 hot-mix liquid manufacturing was added, followed in 2022 by an automated liquid filling line for bottles. Towards the end of 2022 PharmaPac re-configured a packaging area with a new clean room for primary filling of powder into sachets and automatic cartonning.”
Another significant investment was made as a result of a major contract awarded to PharmaPac early in 2023, to undertake blister packaging and cartonning of a licensed soft gel product. The high-speed fully integrated automated blister line should be in full production by the end of 2023, supplying commercial stock.
“Through this investment in high-speed blistering capability, PharmaPac is well suited to providing low-cost and high-quality blistered products to the market,” says Lewis, noting that the continued investment by PharmaPac in modern equipment means that the company can continue to meet the needs of any customer and offer a fast, flexible, and adaptable solution.
Close engagement with customers
He further reflects that the last few years have demonstrated the benefits that CMOs have brought to the delivery of a continued supply of pharmaceutical goods and services for clients. “The closer engagement of customers with CMOs has become firmly established as a permanent and essential part of business planning. CMOs have confronted and overcome a host of challenges for clients, from material/logistics shortages and supply chain disruption as well as staffing issues and have delivered solutions in a difficult trading climate.”
“Over the last few years, we have seen robust growth in the collaborative development of effective substitutions. We are working with our customers and suppliers to ensure that patient needs are met and are constantly reviewing packaging base materials that are more readily available and which are potentially suitable for meeting the product specification and needs of the brand owners.”
Lewis also affirms that as a key contractor to the pharmaceutical and healthcare market it is imperative that PharmaPac demonstrates its corporate and social responsibility to all its customers. “We ensure our procedures and policies are always up to date and are regularly audited on site by Sedex. A recent audit by Ecovadis has resulted in PharmaPac receiving a bronze award for sustainability which we are extremely proud of.”
Promising prospects
Speaking about the company’s plans for the future, Lewis affirms that PharmaPac aspires to become a significant global contract manufacturer for healthcare products by continuing to provide an exceptional service. “We will be supporting our customers to design new solutions, reduce costs, and increase speed to market for global pharmaceutical, medical device, consumer healthcare, nutraceutical and veterinary companies.”
To this end, more investment is planned. “As a result of a new contract, PharmaPac will be investing in a purification plant that will take town’s water and convert it into purified water required for the manufacturing of creams and gels. Consequently, we will also be installing a steam generation unit and additional manufacturing vessels, plus an automatic tube filler with cartonner to support this project,” says Lewis.
In line with these developments, the company is looking to significantly increase staff numbers and is open to present its facility to the public. “PharmaPac always welcomes on-site visitors, including potential customers, suppliers, as well as future employees,” affirms Gareth Lewis.
Summarising the outlook for the future, he affirms that growth is a key driver for the business, and that PharmaPac continually looks to invest in new equipment and processes. “Projects have been identified that will require several million pounds of investment over the next few years to ensure we stay at the forefront, maintaining the quality and consistency that our customers expect.”
