Performing Double Duty - Pharmaceutical Technology

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Performing Double Duty
Many child-safe package designs help improve compliance and provide tamper evidence.


Pharmaceutical Technology
Volume 35, Issue 8, pp. 37-39


Intini’s Bend and Peel Easy Tab wallet with a folded double card provides child resistance protection for high pill counts.
One patented wallet pack seals a non-CR blister into a paperboard sleeve to create a CR package (howell•CR•III package, Howell Packaging). A configuration using paperboard with recycled content also has earned an F = 1 rating. At least two machines can join the blister card and paperboard. One is capable of running 50–75 packs/min (wallet pack machine, Howell Packaging), and another produces more than 200/min (Blister Card/Wallet Machine, MGS Machine).


Intini’s F = 1 Easy Lock wallet unlocks the blister card by pushing up a die-cut tab. An interior stop prevents removal of the card from the sleeve.
Another wallet concept relies on an open-ended, flat paperboard carton with matching oval windows in the top and bottom panels. It also incorporates a die-cut tab in the blister to lock the card in place. Pushing the die-cut tab up unlocks the blister and allows the card to slide out. An interior stop prevents the card from being completely removed from the seal- or tuck-end carton. After the user removes the dose by pushing it through the lidstock, he or she slides the card back into the carton and presses the tab down to lock it in place. Poly-coated paperboard protects the carton from tearing, and the configuration is often compatible with existing blister tooling. Adult testers rated the design as easy to manipulate. Toddler testers had such difficulty with access that the package earned an F = 1 rating (F1 Easy Lock wallet, Intini Marketing).


Most child-resistant wallet designs from Intini accept cold-formed foil blisters as well as standard blisters.
A similar pull-out–push-in design with an F = 1 rating earned praise from the Arthritis Foundation for its ease of use. The integrated carton, blister card, and leaflet or insert features an easy push-through lidstock plus a calendar or set of dosing instructions to help the patient remember when to take a pill. To earn the commendation, the package underwent a series of rigorous tests at the Georgia Institute of Technology's Research Institute, an independent laboratory that analyzes products for people with functional limitations resulting from arthritis. The study participants, who have moderate to severe arthritis, found the design easy to use, and six out of eight participants would recommend the design to friends with arthritis (Dosepak Express, MeadWestvaco).


A child-resistant wallet design from Intini holds a blister card with a dual-chamber configuration to provide access to doses that are too fragile to be pushed through lidding material.
If a capsule or tablet is too fragile to be pushed through lidding material, CR protection is still possible through a folded, heat-sealable paperboard card with a perforated tab and a dual-chamber blister (i.e., one empty and one full chamber). To access the dose, the user tears away the paperboard tab, presses down on the empty blister chamber to break the lidstock, and tears the lidstock to free the dose in the second chamber. Suitable for clinical trials, the design also is licensed for use by the Veterans Administration (Peel Peel wallet, Intini).

For sturdier doses, a similar concept starts with pressing out a perforated tab with a key, tearing the tab away to expose the foil lidstock, and pushing the pill through (3CPak, Colonial Carton) A low-volume version for clinical trials also is available (Key-Pak, Keystone Folding Box).

A similar paperboard wallet design with perforated tabs calls for bending the edge of the wallet to gain access to the tab. When the tab is removed, a layer of paperboard with an I-shaped die cut remains. The die cut reduces the force needed to push the pill through the lidstock and paperboard layer. The intuitive design eliminates the need for printed instructions, thus leaving more space for product information and graphics.

For regimens with high pill counts, a folded double card can be housed in an open-ended, tuck-style carton. Blisters can be traditional film–foil or cold-formed foil. Ranking as the first CR and SF blister pack approved by the Canadian Standards Association, the design also meets US and European requirements for CR packaging (Bend and Peel Easy Tab wallet, Intini).


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