Method of making a customized packaging film for a pharmaceutical product

A method of making a packaging material having optimum barrier properties for a pharmaceutical product consisting of the steps of:

• (a) determining sensitivity values of the pharmaceutical product for environmental factors consisting of each of humidity, temperature, light and gas;
• (b) after step (a), determining the sensitivity values of the pharmaceutical products towards inherent properties consisting of each of gas liberation tendencies, drug release properties, dimensional properties, hygroscopicity and degradation;
• (c) after step (a) or (b), quantifying each of the sensitivity values for the environmental factors obtained in step (a) and after step (b) quantifying each of the sensitivity values obtained in step (b);
• (d) after step (c), determining threshold values of the sensitivity parameters from which the pharmaceutical product should be protected;
• (e) after step (d), determining, based on the threshold values obtained in step (d), barrier properties of a group of packaging materials consisting of polymers, papers and metal, to determine the optimal thickness of said materials for packaging the pharmaceutical product in a film having at least one layer, said barrier properties consisting of each of water vapor, transmission rate, thermal conductivity, gas transmission rate and percentage light transmittance;
• (f) after step (e), determining optimal physical properties of the packaging material based on properties consisting of each of WVTR, light transmission, gas transmission, thermal conductivity, thickness, dimensional stability, impact strength, tensile strength, elongation at peak load, heat seal strength, forming temperature, toxicity and stretchability;
• (g) after step (f), selecting at least one packaging material and its thickness such that its barrier properties and physical properties satisfy all the determined threshold values of the sensitivity parameters of the pharmaceutical product determined in step (d);
• and
• (h) after step (g), converting the selected one or more packaging materials into a packaging system defined by at least one layer,
• wherein the thickness of the packaging system is from about 5 to about 1000 microns, but is no thicker than necessary to satisfy all of the determined threshold values of the sensitivity parameters obtained in step (d).