Plasma Treatment of Inhaler Cans for Bespak
The Challenge
Bespak, a division of Consort Medical, the leading manufacturer of metered dose inhaler valves, dry powder inhalers and medical inflation check valves, asked Ceram to help investigate the plasma deposition of a surface modifier on the internal walls of inhaler cans. Modifying the surface imparts valuable properties such as lower friction, improved waterproofing, reduced surface energy and a lower drug deposition tendency.
Existing intellectual property rights for this process eliminated a number of potential gas mixtures. Bespak were therefore interested to investigate alternative gases in terms of their ability to modify the surface and to provide the required surface properties.
What Ceram Delivered
Ceram implemented a work plan which had several stages:
- Investigation of the surface composition of known inhaler can surfaces to set a baseline
- Development of an in-house plasma unit capable of utilising fluorinated polymers
- Operational runs of several batches of samples through the plasma unit with various gas combinations to deposit a range of coatings onto a known substrate
- Use of XPS (X-Ray Photoelectron Spectroscopy) surface analysis to determine the surface composition after deposition to establish to what extent the new gas combinations had modified the surface compared to what was required.
By careful selection of the plasma conditions, and the gas mixtures, Ceram was able to determine the most effective gas composition which would enable Bespak to achieve successful treatment of the internal surfaces of inhaler cans without infringing existing patents.
Value to the Client
This investigation is a typical example of the kind of small-scale development trial carried out for clients by Ceram. In this case we were able to determine the best mix of gases for the surface modification required. By subcontracting this development work to Ceram, Bespak’s existing large scale plasma units were able to continue production without interruption. The development study findings were then scaled-up using the optimum gas composition and process conditions saving further valuable manufacturing capacity.
By utilising Ceram for this investigation Bespak were able to draw on Ceram’s vast knowledge of surfaces and their expertise in plasma deposition technology without the need to set-up a plasma unit in-house for this development. By outsourcing this work, Bespak eliminated the possibility of contaminating their existing plasma kits and ensured that production capacity was not affected.
