We relieve your packaging lines of the burden of special orders and small batches, reduce changeover times and establish stable processes for long runs.
This ensures your packaging processes remain predictable and can be scaled up seamlessly.
The result is clear handover points, consistent process quality and a solid foundation for future automation.
Our objective: We support production and quality teams in safely developing packaging processes from product approval through the ramp-up phase towards automation.
Benefits for production and quality
Greater stability on validated production lines
Pre-assembled packaging components reduce special operations, manual intervention and frequent changeovers. Production lines run more consistently and can be planned more effectively.
Higher OEE and better capacity utilisation
Small batches and special configurations no longer tie up production line capacity. Production resources are used specifically for long runs.
Reduced burden on staff and organisation
PrePackaging steps are outsourced without compromising on quality or transparency. Internal teams gain time for value-adding core processes.
Reliable scaling towards automation
Packaging and assembly are designed from the outset to allow for automated processing later on without the need for design changes.
![[Translate to English:] Head Regional Business Team Michael Nemeth](/fileadmin/_processed_/e/a/csm_Michael_Nemeth_82a3c07384.png "Contact Person Michael Nemeth")
What we mean by PrePackaging
Our PrePackaging service comprises pre-assembled, ready-to-pack solutions consisting of Folding cartons, leaflets and Labels. The individual components are developed to work in harmony and prepared to ensure a reliable production process.
The focus is on product-specific PrePackaging steps such as:
Assembling folding cartons
Special gluing for specific requirements
Bundling leaflets
Combining several components into a manageable unit
Further PrePackaging steps are possible depending on requirements and project specifications.
Quality, documentation and handover points
Quality, documentation and handover points
PrePackaging is fully integrated into our quality-assured processes. All work steps follow defined procedures with clear responsibilities and documented handover points.
For quality teams, this means:
traceable processes
clear interfaces
reproducible results throughout the entire product lifecycle
GMP-compliant procedures are a given and an integral part of our approach.
Closely integrated with the product and sustainable
Closely integrated with the product and sustainable
The PrePackaging Service is not a standalone add-on, but part of our system supplier model. It is closely integrated with our leaflets, folding cartons and labels. This integration enables:
consistent coordination of all packaging components
less coordination effort
greater process reliability throughout the entire secondary packaging process
Sustainability as a positive side effect
Stable processes, less waste and consolidated packaging steps contribute to a more efficient use of resources. Sustainability here stems from process quality and planning reliability, not from additional effort.
The benefits of the Faller PrePackaging Service:
The PrePackaging Service is designed to ensure the technical and quality integrity of packaging processes in the pharmaceutical sector, free up capacity and maintain long-term scalability.
Reducing the workload on validated packaging lines
Special orders, small batches and manual steps are carried out outside your production lines. This minimises disruption to existing processes and ensures smooth operations.
Higher OEE and more stable processes
Fewer changeovers and clearly defined packaging steps lead to predictable long runs and better utilisation of your lines.
Predictable processes from approval to series production
Packaging and PrePackaging steps are developed to accompany the entire product lifecycle – without subsequent fundamental changes.
Scalability towards automation
The packaging design takes into account future automated processing right from the start. A design change during ramp-up is not required.
Reduced investment risk for market launches
Production capacities can be built up flexibly without having to invest in new machinery or additional lines at an early stage.
Cost-effective implementation of small and medium-sized batches
PrePackaging enables cost-effective solutions for small quantities without tying up internal capacity or destabilising processes.
Product-oriented integration of all packaging components
Folding cartons, leaflets and labels are developed in coordination with one another and provided pre-assembled.
Traceable handover points and consistent process quality
Clear interfaces, defined workflows and documented handovers support quality teams in their assessment and approval processes.
Sustainability as a result of efficient processes
Consolidated packaging steps, reduced waste and the use of recyclable cardboard materials contribute to improved resource utilisation.
FAQ PrePackaging Service
The PrePackaging Service is particularly suitable for long runs, products with consistent volumes, and situations where special requirements, small batches or manual steps would compromise the efficiency of validated production lines.
PrePackaging also provides a reliable solution for product launches or transitions to higher levels of automation.
PrePackaging is not simply the outsourcing of individual work steps, but an integral part of our system supplier approach that is closely aligned with the product.
Development, packaging components and PrePackaging processes are all coordinated. This reduces interfaces, increases process reliability and makes scaling easier.
The PrePackaging Service is designed for predictable production scenarios and long runs.
Whether its use makes sense from both a cost and operational perspective depends on the product, volume, line configuration and internal resources. This is precisely what we will clarify together during a consultation.
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