Medical Products
System for transdermal therapeutic systems and oral film strips

Precision cutting and production with OPTIMA

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In the pharmaceutical world, these are playing an increasing role: transdermal therapeutic systems (TTS) are applied to the skin, where they release active ingredients in a controlled manner. 

The advantage is that the drugs directly enter the bloodstream so they do not affect the gastrointestinal tract or liver.As a manufacturer, you face a number of challenges in TTS development and production: the highly viscous and pressure-sensitive adhesives require both cohesive and adhesive properties. They must reliably release the active ingredient without irritating the skin or triggering allergies.

In this case, you will benefit from our core competence: handling materials with diverse physical properties. Systems with constant web tension, precision cutting quality, and in-line inspection ensure safe and highly efficient processes. When are you going to opt for the end-to-end, cost-effective solution for converting, and the primary and secondary packaging we offer?

Transdermal patches run on a conveyor belt through a machineTransdermal patches run on a conveyor belt through a machine
Hand in hand for maximum efficiency This is how you benefit from our expertise in manufacturing and packaging pharmaceutical products

We work with you to configure your system technology on a platform basis. You can count on the winning triple formula for success: excellent plant efficiency, output, and utilization of your raw materials.

Cutting stations, laminating and delaminating units, or printing systems: with Optima, all processes seamlessly intertwine. The result is the careful and economical use of your valuable active ingredients. Right from the configuration stage, we ensure your system meets all the requirements of the regulatory authorities.  We also offer machine qualification and validation in compliance with the FDA and EMA.

If needed, our technical center can let you use a testing machine for the new and further development of transdermal patches and oral film strips. Afterward, we will transfer the processes or machine modules developed there into a production machine tailored to your needs.

Overview of transdermal patches and oral film strips

You produce and package all this with OPTIMA

  • Monolithic/matrix patches
  • Reservoir patches
  • Microneedle technology 
  • Oral dispersible film strips
  • Transmucosal products
Transderm medical devices
Production steps at a glance
Production steps at a glance
Process graphic of the OPTIMA TDC
1. Cutting
2. Printing
3. Product inspection
4. Sealing
5. Packaging inspection
6. Cutting and stacking
7. Cartoning
Process graphic of the OPTIMA TDC
1. Cutting
Detailed view of the cutting station of the RONJA TDC 125

The cutting stations for kiss-cut and contour-cut operate with high precision and maximize the use of your material. They are designed for simple, quick format changes. Select Stations on or off, depending on the product design.

2. Printing
One plant prints products

The system will print your products according to your specifications. There is a range of printing processes to choose from. After printing, cameras check the result to ensure that only flawlessly printed products leave your premises.

3. Product inspection
Detailed view of the LEUKOMED 3-33 during product inspection of medical products

Is everything as it should be? This is checked by sensors and camera systems during the one hundred percent in-process monitoring. Depending on the application, matrix or line scan cameras are used for this purpose. Thanks to transmitted or reflected light illumination, they accurately identify even the smallest defects. This means that only acceptable items make it through the process.

By the way, the camera systems also perform complex web control tasks – making your system even more effective.

4. Sealing
One plant seals products

Your freshly made transdermal patches and oral film strips are sealed in pouches by a plate sealing module. The sealing unit is supplied with one or multiple lanes. Good to know: sealing pressure, sealing temperature, and sealing time are continuously monitored and logged by your system. In addition, the packaging film can be printed in a variety of ways and the print checked afterward.

5. Packaging inspection

Sensors and camera systems verify the finished packaging. Thanks to one hundred percent in-process control, you can rest assured that only flawlessly packaged products pass this test.

6. Cutting and stacking

Pouches are cut and provided with a tear flap, if necessary. Afterward, the system stacks them in the right quantity for the folding carton. 

7. Cartoning

The cartoner inserts the counted product stacks into folding boxes and closes them. The folding boxes are then imprinted. Now your transdermal patches or oral film strips are ready for subsequent transport packaging.

Plant technology

Built-in advantages for you

Detail of a machine for rail transport of products
High-precision web transport

In Optima's synchronized systems, web transport systems convey and position your components accurately and reliably down to the tenth of a millimeter.

One person replaces a pulley in the machine
Cleaning made easy

Instead of time-consuming cleaning, simply swap them out. Parts, such as deflection rollers, cutting systems, or web feeders that come into contact with the product can simply be removed for cleaning – which saves both time and effort.

Wolfgang Pyrags
Do you have a current project or open questions?
Wolfgang Pyrags
Key Account Manager
+49 791 506-1192 customer.info@optima-packaging.comWrite e-mail
Wolfgang Pyrags
Wolfgang Pyrags
Key Account Manager
Flexible production of transdermal patches and oral film strips

Manufacturing plant for laboratories through to large-scale production

From a compact converting machine for development and clinical trials to a super-fast manufacturing line that includes primary and secondary packaging:  together, we will configure your ideal system.

OPTIMA TDC 125
OPTIMA TDC 125 | Intermittent | Lab machine | + Converting
OPTIMA TDC
OPTIMA TDC 125 | Intermittent | Lab machine | +Converting | +Pouch Packaging
OPTIMA TDC continuous
OPTIMA TDC 125 | Continuous | Small volume production | + Converting | + Pouch packaging
OPTIMA TDC 300
OPTIMA TDC 300advancedLarge volume production+Converting+Pouch packaging+Secondary packaging
Plus points

This is what you can count on with OPTIMA systems

Scalable Grow safely. All the processes relevant to your product are first developed on a laboratory scale and then ramped up to large-scale production. This allows you to match your output to demand – without compromising on process reliability.
Can be validated Fulfill requirements automatically. All manufacturing and packaging processes can be validated according to FDA and EMA requirements and transferred to high-volume machines.
Expandable Increase your frequency. Thanks to its modular design, the system will grow with your needs. This means the basic machine can be upgraded from an intermittent to a continuous process.
Can be integrated Stay flexible. You can also integrate individual process stations or even entire machine modules – such as pouching – at a later date at any time.
Reproducible Produce a consistent quality of product. All production parameters are stored in programs.

Maximum performance in numbers

1.200
products/minute (multi-web) 
60
meters/minute web speed
320
millimeter web width (special widths on request)
Man puts oral film strip on his tongue
TDC125 laboratory machine

System in action

Oral film strips and transdermal patches are a well-tolerated form of administering medication. The OPTIMA TDC 125 offers you an ideal entry into producing small to medium quantities. It is also ideal for product development and clinical testing in the lab. The system can produce up to 200 products per minute.

Wolfgang Pyrags
Do you have a current project or open questions?
Wolfgang Pyrags
Key Account Manager
Wolfgang Pyrags
Wolfgang Pyrags
Key Account Manager
+49 791 506-1192 Write e-mail
Wolfgang Pyrags
Do you have a current project or open questions?
Wolfgang Pyrags
Key Account Manager
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