Growing up, we all learned the lesson, “It’s not what you say, it’s how you say it.” Similarly, when it comes to healthcare, sometimes it’s not just about what medication you take, but how you take it. One delivery method that has been around for over forty years but is growing in popularity is the transdermal patch.
In this article, we’ll scratch the surface of the benefits and design challenges for creating a high-quality and successful transdermal patch product.
Transdermal patches are designed for topical delivery of a medication or other substance. The patch is applied to the user’s skin, where a small, controlled, and consistent dose of the drug is absorbed into the skin and enters the bloodstream.
There are several advantages to using transdermal patches. They can be more convenient, non-invasive, and less painful than other drug delivery methods such as oral pills and intravenous injections. For caregivers and medical professionals, transdermal patches can improve medication adherence and decrease abuse. The patches can be especially beneficial for patients that require long-term and consistent therapeutic levels. In other words, the patient just needs to apply the product once – and the transdermal patch removes the possibility of missing a dose. Another benefit is that because the medication enters directly into the bloodstream, the drug isn’t broken down or affected by the body’s digestive processes.
However, there are a few limitations to keep in mind. While transdermal patches have been FDA-approved since 1979, not all types of medications can be administrated in this manner. Due to the defensive nature of the skin, the molecules of the active ingredient must be small enough to pass through and enter the bloodstream.
While the development process of transdermal patches can be long and complicated, working with an experienced manufacturing partner with the right materials expertise can improve speed to market and overall product quality.
There are two broad markets for transdermal patches. The most established and highly regulated one being pharmaceuticals. Common medications used with transdermal patches include nicotine, scopolamine, rivastigmine, buprenorphine, and fentanyl.
An emerging market for transdermal patches is nutraceuticals. Used for recreational, supplemental, or general wellness purposes, these over-the-counter products are minimally regulated. Some popular nutraceutical applications of transdermal patches include cannabinoids (CBD, CBN), Vitamin B12, and Vitamin E.
While there are multiple constructions of a transdermal patch (which we’ll get to in a bit), most products consist of five layers or components.
Images courtesy of 3M
Depending on the drug being administered or the wear-time of the product, transdermal patches can be constructed in a few different ways.
Before you can get your transdermal patch product into the hands (and on the skin) of consumers, there are many design challenges and manufacturing processes to tackle. As with any medication, it starts by getting the drug formulation just right. For transdermal patches, there’s the extra element of ensuring a controlled and consistent dosage. Another factor is the duration of use, which will influence both the drug formulation and the material selection of the patch (including stick-to-skin adhesives). Aside from the drug delivery mechanism, it’s important to consider comfort, ease of use (both applying and removing from the skin), and aesthetics of a transdermal patch.
Once the product has been thoroughly designed and tested, the manufacturing process of transdermal patches can be broken down into three main steps.
At Tapecon, we have experience providing design consultation and custom converting for the medical device and pharmaceutical industries. Our facility is ISO 13485 certified and FDA Registered, with clean room converting capabilities. Plus, as a 3M Preferred Converter and converter of other reputable medical material suppliers, you can be confident you’re getting the highest level of converting expertise along with industry-leading materials for transdermal patches.
With over 100 years of manufacturing experience, Tapecon works with product teams to solve challenges, create products, and enhance lives. Learn more about our skin tapes and patches applications.