A pioneering packaging concept developed through a collaboration between SCHOTT Pharma, Schreiner MediPharm, and Körber Pharma is redefining safety and sustainability in pre-filled syringe packaging. The innovative system combines the SCHOTT TOPPAC® infuse COC syringe, a newly designed specialty cap, and Schreiner MediPharm’s Cap-Lock Label to deliver a blister-free solution that ensures product integrity while significantly reducing environmental impact.
The breakthrough lies in the cap’s design, which aligns with the diameter of the syringe barrel, allowing the Cap-Lock Label to be securely applied across both components in a single, reliable process. This label serves as a tamper-evident seal, irreversibly breaking upon first opening, giving users a clear visual indication if the syringe has been previously accessed.
“With this solution, we ensure maximum product safety and integrity—from manufacturing to final use,” said Dr. Nadine Lampka, Senior Product Manager Pharma-Security at Schreiner MediPharm.
Beyond safety, the new system offers substantial economic and environmental benefits. The elimination of traditional blister packaging reduces plastic use by up to 80%, enabling more compact logistics and significantly lower carbon emissions. A case study illustrates the impact: transporting 10 million 5 ml syringes from Hamburg to New York could require 16 fewer shipping containers, avoiding approximately 87,400 kilograms of CO₂ emissions.
The innovation was showcased at Pharmapack 2025 during the Alliance to Zero Workshop, “How to Build Sustainable Value Chains Together,” where it drew strong interest from the pharmaceutical community.
“The positive response at the trade fair highlights the urgent need for sustainable packaging in pharma,” noted Lidia Smith, Sustainability and Product Manager at Körber Pharma. “Our collaboration with Schreiner MediPharm and SCHOTT Pharma is a major step toward building a greener supply chain.”
In addition to its tamper-evident function, the Cap-Lock Label also offers protective features traditionally handled by blister packs. These include gas barrier properties, multi-level UV and light protection, and the potential integration of RFID chips for unit-level tracking and digital first-opening indication. The extended label area can be customized with product information, color coding, and branding elements.
The optimized system supports volume-efficient packaging, with the COC syringe and functional label packed in a top-load cardboard box from Körber Pharma made entirely from mono-materials. This enhances manufacturing and distribution efficiency, while further reducing storage and transport requirements.
Schreiner MediPharm continues to expand its line of sustainable, functional labels with additional solutions like Needle-Trap Secu and Syringe-Closure-Wrap, both offering secure, blister-free packaging alternatives.
Together, these innovations mark a significant step forward in aligning pharmaceutical packaging with the industry’s sustainability and safety goals.