When a pharmaceutical company suddenly lost its packaging supplier, it faced a high-stakes challenge: how to source new nasal spray bottles fast, without disrupting its production line or compromising product performance.

The customer needed 20 ml and 30 ml HDPE bottles for two separate nasal spray formulations. The main challenge was that these bottles had to be precisely engineered to fit an existing APTAR spray pump system, with no room for error.

The project posed some demanding technical and regulatory requirements:

• Tight dimensional tolerances at the bottle neck to ensure leak-free pump integration
• Accurate internal bottle depth to match the pump’s dip tube
• Use of FDA-grade materials in full compliance with U.S. pharmaceutical regulations

The customer was under immense pressure as he needed a seamless transition to avoid gaps in the supply chain as any delay would risk product shortages in key markets.

Rapid customization, zero compromise

LOG Pharma’s R&D and engineering teams immediately tackled the challenge. Leveraging years of experience in precision pharmaceutical packaging, we designed two custom HDPE bottle formats from the ground up.

Our approach focused on speed without sacrificing quality:

• We fast-tracked bottle geometry design based on APTAR’s technical specs.
• Precision tooling was developed to meet the strictest tolerances for neck finish and bottle depth.
• FDA-compliant materials were selected to meet all relevant U.S. regulatory standards.
• Throughout the process, we worked closely with the customer, providing ongoing updates and incorporating feedback in real time.

The result was a smooth, on-time solution. The bottles met all technical specifications and integrated perfectly with the existing APTAR pumps, eliminating the need for any changes to the customer’s filling lines or packaging processes.

Most importantly, the pharmaceutical company was able to maintain uninterrupted product availability preserving both business continuity and patient access.

This project highlights LOG’s ability to move fast, solve complex challenges, and deliver custom-engineered packaging solutions under pressure.

Tags: APTAR pumps, FDA compliant, HDPE bottles, LOG Pharma Primary Packaging, Nasal spray formulations