In pharmaceutical packaging, consistency, hygiene, and dosing accuracy are non-negotiable. For liquid oral formulations like Digene suspension, sachet packaging must deliver precise volumes at high speeds while meeting stringent regulatory and quality standards.

PacTech Solutions recently supported Abbott Healthcare Pvt. Ltd. with the supply and implementation of a high-performance stick pack machine designed specifically for Digene liquid sachet packaging. The solution was engineered to ensure accurate dosing, reliable sealing, and stable output under continuous production conditions.

Packaging Challenges in Liquid Sachet Manufacturing

Liquid pharmaceutical products present unique challenges during packaging. Variations in viscosity, temperature, and flow behavior can directly impact dosing accuracy and seal integrity. In the case of Digene suspension, maintaining uniform 10 ml dosing while preventing leakage or contamination was a critical requirement.

Additionally, pharmaceutical sachet lines must support traceability, validation, and repeatability without compromising on production speed. Any deviation can impact patient safety, regulatory compliance, and brand trust.

The Packaging Solution Delivered

To meet these requirements, PacTech Solutions supplied a multi-lane Vertical Form Fill Seal stick pack machine configured for liquid applications. The system is designed to process heat-sealable films and produce accurately formed sachets at high speeds, configured to meet Abbott’s required output rates.

The machine incorporates a pressurized product feed hopper, precision flowmeter-based dosing, and independent nozzle movement synchronized with film pulling. This configuration minimizes splashing, prevents seal contamination, and ensures each sachet receives a consistent dose.

All product-contact parts are manufactured using pharmaceutical-grade stainless steel, supporting hygiene, cleanability, and long-term durability.

Designed for Compliance and Process Control

Beyond mechanical performance, the solution is built to support pharmaceutical validation requirements. The system follows GMP-aligned design principles and includes provisions for Clean-In-Place functionality, level detection, film break detection, and rejection of non-conforming sachets.

Advanced HMI controls allow operators to monitor production parameters, manage recipes, and track output data in real time. This enables stable production while maintaining full visibility and control over critical packaging variables.