Production and storage

Precision and responsibility in secondary packaging

Modern pharmaceutical production and GMP-compliant packaging solutions for small and large batches, with a focus on quality and efficiency.

Our production lines process a wide range of pharmaceutical formats, including: Drug delivery devices such as pens, autoinjectors, inhalers, oral films, or infusion sets.

Primary containers such as pre-filled syringes, cartridges, vials, ampoules, plastic and polyethylene bottles, infusion bags, as well as blister packs.

Accessories such as safety pins, pen needles, standard needles, or vial adapters. Thanks to Twin-Speed technology, different product flows can be processed simultaneously and independently. This significantly increases flexibility and enables rapid format changes.

Our production lines meet the highest industrial standards:

  • Three feeding sections and six feeding systems for hybrid products.
  • Combination of plastic and cardboard processing with a focus on product protection and sustainability.
  • Digital process control with serialisation, aggregation, and SmartControl systems for continuous traceability.
  • Re-feed mechanisms and intelligent ejections minimise waste and protect valuable pharmaceutical products.
  • Compact design (approx. 10.95 m long) reduces space and energy requirements, while modular extensions extend the life cycle.

  • Batch sizes: Our lines flexibly cover batch sizes ranging from smaller quantities up to larger five-digit quantities – for ampoules, vials, and pre-filled syringes/pens.
  • High process reliability thanks to careful handling of sensitive products.
  • Customised packaging styles for specific requirements in the pharmaceutical and healthcare industries.

Sustainability and future prospects in secondary pharmaceutical packaging. In addition to technological innovations, Complex Pharmaceuticals focuses on sustainable packaging concepts to minimise the pharmaceutical industry’s ecological footprint. Through the use of recyclable materials, environmentally friendly printing processes, as well as energy-efficient packaging machines, the company actively contributes to the reduction of waste and emissions. Through these developments, Complex Pharmaceuticals is positioning itself as a key player in the pharmaceutical industry, actively driving medical progress through continuous innovation. Sustainability is firmly integrated into our production:

  • The switch to cardboard significantly reduces fossil-based plastics.
  • Energy efficiency through compact lines, digital controls, and high performance.
  • Waste avoidance through precise handling and re-feed mechanisms.
  • Recyclable solutions: Cardboard or plastic trays, “tray-free” packaging, blister packaging.
  • Long life cycles through modular expandability and retrofittable technology.

A modern high-bay warehouse complements the packaging lines:

  • 4,500 pallet spaces (15–25 °C) and 1,000 pallet spaces (2–8 °C).
  • Complete traceability thanks to digital control and monitoring systems.
  • Automated processes for efficient order picking.
  • Energy-efficient cooling technology and modern building technology reduce the ecological footprint.

As an Austrian company, we have clearly focused on the EU GMP Guidelines and, as a GMP-certified company, we consistently work in accordance with these standards. In addition, MDR and ISO 13485 as well as US FDA requirements have already been incorporated into our project planning and will complement our regulatory capabilities in the near future. In this way, we ensure that we can respond flexibly to international markets.

Cutting-edge technologies in active pharmaceutical ingredient (API) development.

Today, pharmaceutical production relies on state-of-the-art technologies that ensure precision, efficiency, and the highest quality standards. Secondary packaging, in particular, is becoming increasingly important in this context: Not only does it ensure integrity and compliance, it also allows flexible adaptation to different requirements – from clinical trials to personalised therapies.

Highly automated production lines and the use of digitally controlled packaging systems enable standard as well as customised packaging to be produced with the utmost precision. In this way, technological advances make a decisive contribution to the safe, efficient, and patient-centred delivery of innovative pharmaceutical products.

Secondary packaging with the highest precision and responsibility

Accelerate your time to market with compliant, scalable contract manufacturing solutions for the secondary packaging of pharmaceutical products.

Our secondary manufacturing combines technological expertise with a clear focus on sustainability. The goal is to package pharmaceutical products safely, efficiently, and resource-consciously – from single doses to complex combination solutions.

The lines process a very wide range of formats and enable flexible adaptation to different market and patient requirements. These include:

Drug delivery devices such as pens, autoinjectors, jet injectors, inhalers, oral films, nasal applicators, infusion sets and syringes.

Primary containers such as pre-filled syringes, cartridges, vials in various sizes, ampoules, plastic bottles or specific polyethylene bottles, infusion bags, and tablet blisters.

Accessories such as safety needles, pen needles, standard needles, and vial adapters. Format changeovers are quick and can be performed independently, thanks to Twin-Speed technology. This allows different product flows to be processed in parallel and quickly, a factor that significantly increases flexibility.

Our secondary packaging lines are designed to meet the highest industry standards. With three feeding sections and six feeding systems, hybrid products such as ampoules, vials, syringes, and pens can be processed. The combination of PE and cardboard processing enables flexible packaging design that focuses on product protection as well as sustainability.

Digital process control ensures continuous transparency: Complete traceability through internal serialisation and aggregation, ease of use thanks to SmartControl systems, and precise, gentle handling of sensitive products. Rejects are minimised through re-feed mechanisms and intelligent ejection systems.

With a compact design and a line length of around 10.95 meters, the main systems require less floor space and reduce energy consumption. Expandable modules and upgrade options significantly extend the service life of the machines.

Sustainability is an integral part of our manufacturing process. Instead of short-term solutions, we focus on long-term optimisation:

  • Switching to cardboard significantly reduces the use of fossil-based plastics
  • Energy efficiency: Short line lengths, digital
    control systems, and high efficiency permanently reduce energy consumption
  • Waste prevention: Precise product handling, re-feed
    mechanisms, and gentle ejection minimise losses and protect valuable pharmaceutical products.
  • Long life cycles thanks to modular expandability and retrofittable technology
  • Blister packaging ensures maximum product safety
  • Cardboard or plastic trays – with a focus on recyclable materials
  • “Tray-free” packaging options for reduced material usage
  • Custom packaging styles to meet complex requirements in the pharmaceutical and healthcare industry

Warehouse logistics at the highest level

A smooth production process does not end at the packaging line – it flows seamlessly into efficient and secure warehouse logistics. The production site has a modern high-bay warehouse that is designed and equipped according to the latest standards in the pharmaceutical industry.

Pallet spaces at room temperature (15–25 °C)

Pallet spaces at cooling temperature 2–8 °C

Clear warehouse structure

The warehouse structure follows clear principles of security, transparency, and efficiency. Digital control and monitoring systems ensure full, continuous traceability of inventory and audit-proof documentation at all times. Automated processes and standardised procedures ensure that products are not only stored under optimal conditions, but can also be commissioned quickly and reliably.

Sustainability as standard

In addition to its functional advantages, the warehouse also stands out for its focus on sustainability. Energy-efficient cooling technology, optimised use of space and modern building technology significantly reduce the ecological footprint. This not only ensures pharmaceutical quality, but also makes an active contribution to a resource-saving value chain.

Our secondary packaging

Formats, product classes, temperature ranges, and regulatory requirements

  • Drug delivery devices such as pens, autoinjectors, jet injectors, inhalers, oral films, nasal applicators, infusion sets, and syringes.
  • Primary containers such as pre-filled syringes, cartridges, vials in various sizes, ampoules, plastic or specific polyethylene bottles, infusion bags, and tablet blisters.
  • Accessories such as safety pins, pen needles, standard needles and vial adapters.

In principle, Complex Pharmaceuticals can process all product classes, as we work exclusively with sealed primary packaging. As a result, the active pharmaceutical ingredient (API) is not relevant for secondary manufacturing, whether standard products or highly potent substances.

With regard to so-called high potents, it should be noted that in the event of glass breakage or damage, special requirements may be imposed on decontamination strategies and risk analyses. However, these relate to handling and safety protocols and not to the technical processability on our production lines.

Therefore, the following applies: Technically, it is irrelevant which API is contained – the decisive factor is the primary packaging material. This allows us to flexibly, safely and efficiently provide secondary packaging for a wide range of pharmaceutical products.

Our production and packaging areas are climate-controlled at +20 to +24 °C thereby ensuring stable conditions for safe and quality-compliant processing. Two different temperature zones are available for storage: Firstly, an ambient storage facility with a temperature range of +15 to +25 °C, which is suitable for the majority of pharmaceutical products.

Secondly, our facilities also include a modern cold storage area with temperatures ranging from +2 to +8 °C, where temperature-sensitive products can be stored reliably and consistently. In this way, we ensure that both manufacturing and storage meet regulatory requirements and the highest quality standards at all times.

As an Austrian company, we have a clear focus on the EU GMP Guidelines and, as a GMP-certified company, we consistently operate in accordance with these standards.

In addition, MDR and ISO 13485 as well as US FDA requirements have already been incorporated into project planning and will complement our regulatory options in the near future. In this way, we ensure that we can respond flexibly to international markets.

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If you have any further questions regarding our services, we look forward to hearing from you.

Contact

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office@complex-pharma.com

Büro

Complex Pharmaceuticals GmbH
Storchengasse 1
1150 Wien | Austria

Telefon

Bürozeiten
Mo bis Fr. 09:00 bis 18:00 Uhr
Tel: +43 1 208 01 34