Mematec Solution
Turnkey Manufacturer of State-of-Art DPI and Powder Formulations

Chronic obstructive pulmonary disease (COPD) is a prominent disorder affecting over 200 million people worldwide. In most cases, COPD patients experience burdening lifestyle changes due to a range of progressive symptoms like breathlessness, cough, sputum production, wheezing, and chest tightness, among others. To treat these patients, doctors primarily prescribe a pulmonary drug delivery device that can effectively deliver drugs to the affected lung tissue in an easy-to-use manner that does not add to their tedious lifestyle but improves it.

Mematec is a world-class manufacturer addressing this need with its laser focus on designing and developing inhalation medical devices comprising capsule dry powder inhalers and multi-dose DPI (MDPI) for COPD treatment. Its extensive portfolio of devices includes Mora Ellipse, Ostrea Haler, Nesat, Torus Haler, Sykona Haler, and Genius Haler, among others, and customized single- and multi-dose DPI creation services.

“Our mission is to work relentlessly on improving our processes and range of engineered pharmaceutical solid inhalation devices to provide a better and more qualitative end-customer experience,” says Markus Mezger, CEO of Mematec.

Unlike commercially available generic DPIs, Mematec’s solution development is turnkey, which means that the devices are developed with the goal of patient/user friendliness through reduction of operating steps. Its use is as simple as open, inhale, close, with all further steps automated in the device. Additionally, Mematec offers corresponding equipment for filling and assembly. Other competencies include in powder formulation, laboratory for filling tests, and laboratory for determination of in-vitro data.

In contrast, Mematec’s devices and powder blends are bioequivalent, boosting their inter-usability and performance. Further enhancing Mematec’s usability is its devices’ high patient-friendliness, which is driven by features like easy capsule loading, improved handling speed, and simplistic design.

Mematec designs and manufactures inhalation devices and powder formulation in-house. These competencies are powered by more than 20 years of expertise in medical device manufacturing, allowing for faster innovation, better precision, and excellent efficiency. Backing this expertise is its ISO 13485:2016 certification and Medical Device Regulation complacency, which ensures end-to-end quality, from powder formulation to end-of-line packaging, while consistently meeting customer expectations.

Moreover, Mematec has designed several blister strip devices (MDPI) together with the whole machines for manufacturing and assembly of the device for production. From an assembly standpoint, Mematec offers Assembly Modules comprising four workstations that allow sporadic manual transfers of products or parts between the workstations, auxiliary stations, and parts suppliers. These workstations are built with partially mechanized fixtures and developed with ergonomic concepts in mind. Using the poka-yoke concept, its fixture equipment is created to ensure safe operation and error free assembly.

Our mission is to work relentlessly on improving our processes and range of engineered pharmaceutical solid inhalation devices to provide a better and more qualitative end-customer experience

Leveraging these capabilities, all Mematec inhaler devices are designed with fewer parts, allowing users to significantly reduce assembly, machining, and tooling costs. These inhalers can be easily assembled through its semi-automatic assembly and testing modules that effectively mitigate staff-driven handling failures. For instance, the new MDPI devised by Mematec for two APIs (Vilanterol + Fluticasone) contains only 7 parts with the same in-vitro data as most devices that comes in 24 parts.

“Our competitors are either device developers of medical products or plastic injection molding companies. Mematec’s competitive advantage comes from having everything from one source and establishing clear regulation of responsibilities, which drives highly efficient and coordinated work,” states Mezger.

At the heart of Mematec’s unrivaled competencies is its seasoned and longstanding expertise in producing high-quality medical equipment with high efficiency and powder compatibility. In the future, it intends to continue providing exquisitely engineered pharmaceutical devices that deliver the desired medication in a highly user-friendly and non-intrusive manner.