Worked with a major test kit manufacturer and laminated foil manufacturer to develop and produce a new type of pouch with desiccant properties. Thysen Consulting was the primary engineering group responsible for pouch design, selection of contract manufacturers and equipment, pouch testing methods, contract manufacturing startup, and packaging documentation. Pouch design and material were recently entered for the Dupont Flexible Packaging Innovation Award.

Developed, tested, and validated a high volume container to reliably ship a pharmaceutical product to Europe while meeting a specification of 2 to 15°C for 86 hours. Also designed a small shipper for refrigerated domestic clinical trial shipments. Thysen Consulting developed all internal packaging components for both projects.

Designed unique internal packaging components to maximize product volume shipped inside a cylindrical container. The packaging was used for shipping a frozen pharmaceutical product in glass vials to using an insulated shipping container. 

Selected, tested, and specified a wide range of materials including thermoforming foil and film, printing inks and ribbons, pressure-sensitive adhesives, bottles, and closures for pharmaceuticals and test kits. Located and qualified vendors.

Prepared specifications for a large variety of packaging components – including paperboard, corrugated plastic and paperboard, foam, and thermoformed designs.

Developed and wrote protocols for package performance testing for several pharmaceutical products. Worked with three testing laboratories in the Bay Area.