Secondary Packaging
Cartoning, labeling, kitting, bundling, overwrapping, and case packing with multi-language capabilities, leaflet insertion, and fully integrated serialization across every line.
OVERVIEW
Secondary packaging transforms primary-packaged pharmaceutical products into finished, market-ready goods. At Meridan, our secondary packaging operations encompass high-speed cartoning, pressure-sensitive and booklet labeling, manual and automated kitting, bundling and overwrapping, and end-of-line case packing. Every secondary line integrates directly with our serialization infrastructure, enabling continuous production from primary packaging through serialized, aggregated finished goods.
Our secondary packaging capabilities are designed for the complexity that pharmaceutical products demand: multi-language labeling for global markets, patient information leaflet insertion with verification, multi-component kit assembly with barcode reconciliation, and promotional packaging configurations. Rapid changeover tooling and flexible line configurations allow us to transition efficiently between product formats, supporting both high-volume commercial programs and smaller specialty runs within the same facility.
CARTONING
Cartoning
Our cartoning lines support both horizontal and vertical carton loading for blisters, bottles, vials, syringes, tubes, and sachets. High-speed intermittent and continuous motion cartoners handle the full range of carton sizes and product configurations, from single-unit retail cartons to multi-count institutional packs. Patient information leaflet insertion, medication guide insertion, and multi-fold booklet insertion are integrated directly into the cartoning process with camera verification of every insert.
Each cartoning line is equipped with carton coding and printing systems for lot, expiration, and serialization data. Carton weight verification, barcode scanning, and tamper-evident seal application are standard across all configurations. Our cartoning operations support printed cartons from all major pharmaceutical carton suppliers and can accommodate complex configurations including multi-product cartons and combination drug-device packages.
- ✓Horizontal and vertical carton loading
- ✓Patient information leaflet and medication guide insertion
- ✓In-line carton coding, serialization printing, and verification
- ✓Tamper-evident seal application
LABELING
Labeling
Meridan's labeling capabilities span the full range of pharmaceutical labeling requirements, from standard pressure-sensitive labeling to complex multi-panel booklet labels for global markets. Our labeling lines handle wrap-around labels, front-and-back labels, top labels, flag labels, and multi-layer peel-back labels that accommodate extensive regulatory text in multiple languages. Booklet labeling supports up to 20 pages of content, enabling single-SKU packaging for products distributed across multiple countries and languages.
Every labeling line features 100% camera inspection to verify label placement accuracy, text content, barcode readability, and serialization data. Our inspection systems compare applied labels against approved reference images to detect any discrepancies in content, positioning, or print quality. Label reconciliation processes ensure full accountability for every label issued, applied, and rejected throughout each production run.
- ✓Pressure-sensitive, booklet, and multi-panel labels
- ✓Multi-language labeling for global distribution
- ✓100% camera inspection and content verification
- ✓Full label reconciliation and accountability
KITTING
Kitting & Assembly
Our kitting and assembly operations support multi-component pharmaceutical packages that combine multiple products, devices, and patient materials into a single finished package. These programs include drug-device combination kits, patient starter kits, sample kits, and co-packaged products where multiple SKUs are assembled into a single carton or tray. Each component is verified by barcode scan during assembly to ensure the correct items, lot numbers, and expiration dates are included in every kit.
Kitting operations are supported by both manual assembly stations with electronic work instruction systems and semi-automated assembly lines for higher-volume programs. Our quality systems include component-level tracking, photographic verification at defined inspection points, and full lot traceability through the assembled finished good. Weight verification provides an additional check that all components are present before the kit is sealed and released.
- ✓Drug-device combination kits
- ✓Patient starter and sample kits
- ✓Barcode-verified component assembly
- ✓Full lot traceability through assembled goods
BUNDLING
Bundling & Overwrapping
Bundling and overwrapping operations create multi-unit packages and provide tamper evidence, moisture protection, and product grouping for retail, institutional, and wholesale distribution. Our overwrapping lines apply clear or printed polypropylene film with tear strips to individual cartons or carton bundles, providing a clean tamper-evident closure that protects product integrity through the distribution chain.
Bundling capabilities support two-pack, three-pack, and multi-unit bundle configurations with banding, shrink wrapping, or carton sleeve application. Bundle labeling and barcode application are integrated into the bundling process to maintain serialization and traceability at the bundle level. Our bundling operations serve both commercial distribution requirements and promotional configurations such as bonus packs and value bundles.
- ✓Polypropylene overwrapping with tear strip
- ✓Multi-unit bundling and shrink wrapping
- ✓Bundle-level serialization and barcode application
- ✓Promotional and value bundle configurations
END-OF-LINE
Case Packing
End-of-line case packing completes the packaging process by grouping finished cartons into shipping cases, applying case labels with serialized aggregation data, and preparing product for distribution. Our case packing operations support both manual and automated case erecting, loading, and sealing, with case configurations ranging from standard RSC cases to display-ready shelf packs.
Serialization aggregation at the case level links individual unit serial numbers to the case identifier, maintaining full traceability from unit to case to pallet. Case labels include all required shipping information, serialization barcodes, and customer-specific markings. Palletizing services include stretch wrapping, pallet labeling, and aggregation at the pallet level for complete supply chain traceability.
- ✓Automated and manual case erecting and sealing
- ✓Serialized case aggregation (unit to case to pallet)
- ✓Palletizing, stretch wrapping, and pallet labeling
- ✓Customer-specific case marking and configuration
TECHNOLOGY
Equipment & Technology
Our secondary packaging equipment fleet includes industry-leading cartoning, labeling, and end-of-line systems from manufacturers recognized for reliability and precision in pharmaceutical applications. All equipment is fully validated and maintained under a preventive maintenance program that ensures consistent performance across production campaigns.
Secondary Equipment Fleet
Cartoning
- Marchesini MA355
Intermittent motion cartoner, up to 150 cartons/min - Syntegon CUT
Continuous motion cartoner, up to 300 cartons/min - Marchesini MA260
Horizontal cartoner with leaflet insertion, up to 120 cartons/min
Labeling
- Herma H400
High-speed pressure-sensitive labeler, up to 400 units/min - NJM Courser
Wrap-around and front/back labeling, up to 250 units/min - Schreiner MediPharm
Booklet and multi-panel label applicator
Related Certifications
- •FDA-registered facilities (21 CFR Parts 210/211)
- •cGMP compliant secondary packaging operations
- •DSCSA-compliant serialization on all lines
- •DEA licensed (Schedule II-V)
- •ISO 13485:2016 (medical device packaging)
- •EU GMP Annex 16 qualified packaging
Related Resources
View Case Study: Multi-Language Labeling ProgramReady to optimize your packaging operations?
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