Pharmaceutical Industry:

New Product Development


  Client:

A major, highly-diversified global pharmaceutical manufacturer that typically maintained tight control (ownership) over development of their own products.

  Problem: The client had a 6-month window of opportunity to develop a new OTC product within one of its divisions but didn’t have the internal resources to meet critical deadlines.

  Approach: The client supplied Tunnell with the API, targeted product specifications, and use of their facilities. Tunnell researched the API and competitive products and generated product development plan for client (plan reviewed and approved by client). Tunnell project team developed multiple candidate formulations and determined key product performance criteria. Design of Experiments (DOE) was used to select lead candidates and arrive at the final formulation. Tunnell project team identified critical quality criteria for API, qualified prospective API suppliers, developed and validated all analytical methods and manufacturing procedures, established acceptance limits/criteria, scaled-up procedures, optimized process parameters (incl: particle size and coating), produced trial, acceptance, and launch lots, developed all project documentation, and transferred accepted, validated process and controls to the Client. This was the first time the Client outsourced development of one of its own products to an external contractor.

  Results: Outcome of effort included:
  • Successful development of product within targeted window of opportunity (delivered process/product 1 month early!)
  • Fastest development time ever experienced by client
  • One of the most reliable processes/products ever introduced by client (no production/quality problems!)
  • Product exceeded market expectations during first two years of introduction (currently in 3rd year)
  • 30-fold ROI to client first year
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