The Combi Pack by Faller Packaging: Reducing costs, increasing efficiency

With its Combi Pack, Faller Packaging combines folding carton and leaflet into one pre-assembled packaging unit. This 2-in-1 solution reduces the Total Cost of Ownership (TCO) and improves the Overall Equipment Effectiveness (OEE). The largest share of costs does not arise in procurement but remains hidden in day-to-day operations on the packaging line — like an iceberg beneath the surface.

Pharmaceutical manufacturers and CDMOs are under considerable pressure: Increasing regulatory requirements, a fast-growing variety of product variants and smaller batch sizes are increasing the complexities and the risk of inefficient processes. The majority of costs incurred are not related to procurement. Day-to-day operations on the production line account for the lion’s share of the costs, caused by the interaction of various components, quality checks and downtimes.

Fewer interfaces, simplified processes

As the acknowledged specialist for folding cartons, leaflets and labels, Faller Packaging integrates the leaflet into the folding carton using hotmelt adhesive in accordance with GMP standards. This pre-assembled solution reduces the number of interfaces and significantly simplifies the entire packaging process. There is no need for separate feeding systems or additional calibration and testing processes, and that also reduces the need for technical equipment along the production line, which is yet another benefit. And the result? Fewer disruptive sources, shorter setup times and minimised maintenance requirements.

Yet another advantage: the Combi Pack solution can be easily integrated into existing packaging lines without the need for major modifications, so additional investments in machinery or feeding systems are generally not required.

Pharmaceutical companies also benefit from a streamlined procurement process: just one supplier, one ordering process and one goods-in inspection. This saves time, reduces coordination efforts and increases process reliability.

Optimising processes, conserving resources

The Combi Pack also makes warehousing a lot easier. Instead of having to plan and store two components, users only have to handle one packaging unit. This saves storage space, simplifies stock management and speeds up the supply of materials to the production line – and what's more, as a resource-efficient, single-material unit, the combined solution supports sustainable packaging concepts thanks to a reduced number of transport movements and minimised handling requirements throughout the supply chain.

Last but not least, users and patients benefit from the clever 2in-1 solution. The integrated leaflet can be easily removed without damaging the carton.

Benjamin Rist, Product Manager at Faller Packaging.

Order a sample Combi Pack here and download the data sheet: https://www2.faller-packaging.com/l/320911/2026-03-24/955zxy