Formulated Solutions Adds Third GMP Aerosol Line

Contract manufacturer Formulated Solutions added a third GMP aerosol production line as it prepares for future customer demand. Featuring the latest cutting-edge technology, the new GMP production line at its Cleveland facility is fully automated from filling to final case packing. The new high-speed line leverages a mass flow filler to deliver exceptional fill accuracy, automated leak detection to ensure high levels of compliance with the US Department of Transport’s (DOT) aerosol regulations and fully automated secondary bundling in support of the demands of retail channel distribution. 

The ability to now run three distinct product lines significantly boosts the company’s production capacity for medicated topical aerosols, including sunscreens, topical analgesics, anti-fungal sprays and more, according to company executives.

With the aerosol packaging market estimated to be worth $7.5 billion this year, and projected to grow 5% a year through 2031, Formulated Solutions’ new line positions it to effectively meet future demand, from initial concept to full-scale manufacturing.

“As consumer and retailer interactions with key market products change, companies are faced with the challenge to innovate, cut costs and accelerate delivery at the same time as maintaining strict quality and safety standards,” said Scott Carpenter, VP-marketing & partner innovation, Formulated Solutions. “Innovation and quality are embedded in our core values at Formulated Solutions. The addition of a second GMP aerosol production line at our Cleveland facility, our third full-scale line in our production network, will ensure we have the flexibility and capacity to deliver on demand for services in this thriving sector, and will help us continue to meet our industry-leading quality standards.” 

Filling Line Features Cutting-Edge Technology

The new line’s functionality allows Formulated Solutions to offer customers the capability to fill two different bulk intermediates sequentially and use two different propellant blends in the same finished product. Cutting-edge technology featured in the new line includes:

• Fully automated button/actuator tipping,

• Placement of overcaps and tamper-evident neck band capabilities,

• Fully integrated automated case packaging,

• Advanced leak detection, and

• Optical character recognition verification to ensure text codes contain product information for tracking aerosols through the supply chain and inventory management are correct and legible.

Formulated Solutions also supports the production of over-the-counter (OTC) medicines, NDA drugs, medical devices, consumer healthcare topicals, nasal sprays and oral dose liquids.