Multi Packaging Solutions (MPS), a global leader in value-added print and packaging solutions for the healthcare, branded consumer and multi-media markets, has brought agility to the consumer launch of Chattem’s Xyzal Allergy 24HR, delivering two million windowed cartons from two MPS facilities in short order, just in time for allergy season.
Until recently, Xyzal, an antihistamine, was previously available only as a prescription medication. In February 2017, Chattem, a company of Sanofi, announced that the FDA had approved its 24-hour formulation of levocetirizine dihydrochloride (Xyzal Allergy 24HR) for OTC treatment of symptoms associated with seasonal and year-round allergies.
Commenting on the news in a recent company press release, Robert Long, Sanofi’s Head of North America Consumer Healthcare, notes, “The FDA approval of Xyzal builds on our heritage of successful Rx-to-OTC switches, and adds another trusted option to our existing portfolio of OTC allergy medications…we look forward to making it available to allergy sufferers across the country, as the latest product in our growing consumer healthcare business.”
The challenge of bringing Xyzal to consumers and pharmacy shelves was complex for a number of reasons. Firstly, Chattem sought to make the product viewable to the consumer by incorporating a window into the design of the carton. The package was to include a literature insert as well as discreet 100% application of checkpoint and sensormatic security tags. In addition to the project’s unique structure specifications, the launch plan also demanded seamless production and delivery of two million cartons five days after FDA approval had been granted.
MPS worked with Chattem to develop several designs for the carton structure that achieved their requirements. After choosing a suitable design, the client proceeded to qualify two MPS facilities to produce the cartons, MPS Indianapolis and MPS Dallas. Careful quality control measures – including specification management and process control – enabled both facilities to maintain a consistent supply. Among the quality control measures implemented was the adoption of a new glue detection process utilizing state-of-the-art equipment.
Travis McDonough, MPS SVP of Quality, notes, “The compressed time frame for this launch dictated that we run the job in two facilities. MPS was able to engineer something that really worked structure wise, perform exhaustive line tests, and ensured consistent performance in a machine filled environment. This project speaks volumes about MPS’s ability to respond to client needs in a consistent fashion even when multiple plants are involved.”
Within a short time frame, MPS had produced two million cartons to support Chattem’s Xyzal launch. The packages were printed and die cut in MPS Indianapolis while the windowing, folding and gluing was produced in both MPS Indianapolis and MPS Dallas. This March, Xyzal will make it’s debut and grace the shelves of major pharmacies across the country.
Pat Borders, MPS Account Executive for Chattem, comments on the project, “This launch was critical for Chattem, and I’m pleased that we were able to deliver above and beyond their expectations. The Xyzal package is a great example of how our team collaborates to make creative and structural concepts a commercial success.”