Modern OPC Ampoule Production for Pharma | Kapoor Glass

When pharmaceutical products need their primary packaging to be safe and secure, the primary packaging container acts as the vessel that ensures the formulation remains safe throughout storage, handling and filling activities. An OPC ampoule is one such container format aimed at controlled opening and secure containment. When choosing a solution for pharmaceutical manufacturers, type of glass, forming process, dimensions, inspection method and opening method can all play a role in how good the pack feels.

Kapoor Glass produces pharmaceutical glass ampoules, manufactured from Type 1 glass, in state-of-the-art production processes, offering a variety of solutions to meet the demands of pharmaceutical applications.

With over 60 years experience in primary packaging, Kapoor Glass uses manufacturing technology, robot inspection and controlled pack manufacturing to ensure consistent glass packaging.

What it takes to make pharmaceutical glass ampoules Though the ampoule appears straightforward, there are many technical details to consider in its production. The glass, for instance, must be of uniform dimension and must have an appropriate cosmetic quality. The completed container must be compatible with filling, washing, labelling, and handling.

Kapoor Glass manufactures clear and amber pharma glass ampoules from 1ml up to 30ml capacity using automated feeding systems and robotic packers to minimise human handling.

Inspection systems assist in controlling dimensions and visual or cosmetic variations throughout the manufacturing process.

In addition to the container and label, packaging choices must include the material and volume of the actual product, the environment in which the product is filled, the manufacturing equipment, and the overall level of compliance required by regulation. Knowledgeable pharmaceutical packaging manufacturers add benefit here, beyond a basic container supplier. Kapoor Glass, which supplies Type 1 neutral borosilicate glass tubing for primary packaging applications to other glass producers, has integrated camera inspection and process control to ensure unique sizing and cosmetic uniformity in all its manufacturing processes.

Opening Systems – An important element of ampoule design The break system on the ampoule can vary according to pharmaceutical use, product type, processing procedure and end-user needs. Kapoor Glass provides a number of options such as Colour Break Ring, One Point Cut, safeOPC and 360-degree score ring configurations. Its safeOPC development aims to enhance the opening experience, and to develop solutions for difficult-to-open ampoules. Dedicated camera systems are employed in the production of OPC ampoules to facilitate inspection and process control.

Controlled environment Pharmaceutical primary packaging is subject to manufacturing requirements as well. According to Kapoor Glass, clean room conditions are maintained in the company’s ampoule production lines. Hot-end camera systems have been employed for dimension control and inspection, and a cosmetic camera inspection could be used to test the print and visual features. Automation with the use of these systems ensures an easier identification of potential variation than manual techniques.

Aside from wide mouth and vials, Kapoor Glass has a range of ampoules for pharmaceutical packaging needs. The range includes Form B ampoules with a straight-stem, Form C funnel-type ampoules, Form D closed or rota ampoules, and Form E Marzocchi ampoules. According to your specific application needs, we can also provide form shapes and sizes. Other options include identification rings, ceramic printing, ammonium sulphate, external silicon coating, and lyophilization ampoules.

Consistency can matter for those manufacturing on high-speed filling lines Pharmaceutical manufacturers on high-speed filling lines may find consistency especially desirable. Dimensional or cosmetic differences can affect handling and operation of downstream equipment. Kapoor Glass sees a heavy focus on automation, inspection and manufacturing controls - its Dimension+ development is designed to ensure higher yields and filling machine efficiency - and its full-scale manufacturing controls prioritise repeatability of dimensional and cosmetic traits.

It’s useful to take into account the knowledge, manufacturing capabilities, quality systems and knowledge to support you as you develop different product requirements, not only for the selection of pharmaceutical glass. Since 1962, Kapoor Glass has been manufacturing glass for primary packaging and today supports pharmaceutical business products on the global market. Its ranges include other formats such as tubular vials, cartridges, perfume samplers and laboratory glassware, giving pharma businesses wider expert support.

Choosing an ampoule supplier thus goes beyond product specifications. Because the challenge is to comprehend how the packaging will integrate with the whole pharmaceutical production process. The application engineer has to examine various features like the quality of glass, size, form of the ampoule, type of the opening system, inspection technology, surface treatment, printing, and filling-line to arrive at the best packaging solution.

Kapoor Glass remains committed to manufacturing at the forefront of technology with a focus on quality primary packaging for pharma. With the use of Type 1 glass, automated production, camera inspection, advanced opening systems, and extensive manufacturing know-how, it offers a viable solution for pharma companies seeking pharma glass packaging.

Looking for trusted ampoule solutions for the pharmaceutical industry?

Get in touch with Kapoor Glass, and share your pharmaceutical packaging needs. Tell us about the capacity required, the number of ampoules, opening system, printing need, surface treatment, filling-line equipment requirements, and so on.

Kapoor Glass can recommend the best packaging options and introduce the right glass container for your pharmaceutical manufacturing needs.

Contact us today for container solutions with a precision focus and decades of experience.