Advancing DPI Blister Filling: From The Original Invention To The Latest Technology

An interview with Carl Jones, projects director at 3P innovation

Dry Powder Inhaler (DPI) formulations present unique manufacturing challenges, especially concerning dose accuracy and contamination due to additives like magnesium stearate. This common lubricant, essential for API release, creates extremely fine dust when handled using vacuum-based filling systems, often leading to contaminated blister strips and failed seals.

Carl Jones, Projects Director at 3P innovation, discusses how the latest advancements in blister filling technology are resolving these long-standing issues. By adapting a compression technique traditionally used in tablet manufacturing, a cleaner process is achieved that forms and delivers a precise, compact dose without using a vacuum. This approach dramatically reduces airborne dust and minimizes sealing failures.

Access the full conversation below to learn more about how this foundational shift in DPI manufacturing sets a new benchmark for accuracy and clean operation.