+44(0)1865 891466 
Customer-Driven Engineering Delivers Reliable Pharmaceutical Capping
How a customer-driven engineering approach helped a pharmaceutical manufacturer achieve capping integrity and efficient changeovers.
In pharmaceutical manufacturing, capping is never “just capping”. Seal integrity, torque accuracy, repeatability, and operator usability all play a direct role in patient safety, regulatory compliance, and production efficiency. For global pharmaceutical service provider Almac Group, selecting the right capping solution for a new oral solid dose packaging line meant choosing a partner who understood those pressures from the outset.
A customer‑driven engineering approach, paired with robust and validated capping equipment, enabled Almac to achieve reliable seal integrity across their lines. The solution also simplified changeovers and provided long‑term confidence in the consistency and performance of their packaging operations.
About Almac Group
Almac Group is a global, privately owned contract development and manufacturing organisation (CDMO), providing a comprehensive range of services across the drug development lifecycle. Serving pharmaceutical and biotech companies worldwide, Almac specialises in clinical trial supply, commercial manufacturing, and oral solid dose packaging, operating to the highest regulatory standards.
With locations in Europe, the United States, and Asia, Almac supports complex clinical and commercial packaging requirements where precision, traceability, and quality assurance are non-negotiable.
The Role: Engineering Coordination for Critical Packaging Systems
When we began working with Almac Group on their latest oral solid dose packaging line, we collaborated closely with Brandon Ruggiero, Engineering Co-Ordinator, who plays a central role in taking new packaging lines from concept through to commissioning.
At the time, Almac was commissioning a new clinical trial dry packaging line for oral solid form bottling. Brandon was responsible for overseeing the line design, managing tooling lead times, and leading the procurement process, all while ensuring the equipment met strict operational and regulatory requirements.
While Brandon had been with Almac for three years, our relationship with the team extended much further back. Cap Coder equipment had already proven itself within their operations, giving Almac confidence that expanding their capping capability with us would deliver both consistency and reliability.
That long-standing partnership meant we weren’t starting from scratch. We already understood Almac’s expectations around quality, compliance, and usability, allowing us to focus on delivering a solution that supported their production goals from day one.
The Challenge: Capping Integrity, Usability, and Changeover Efficiency
For pharmaceutical packaging lines, the risks associated with inconsistent torque or poor accessibility are significant. Almac needed a solution that would:
- Deliver guaranteed seal integrity
- Support repeatable, validated torque
- Enable efficient changeovers for varying pack formats
- Be operator-friendly, reducing training time and human error
- Integrate seamlessly into both existing and future line configurations
In addition, the equipment had to meet the expectations of a regulated environment where audit readiness and long-term reliability are essential.
The Solution: Cap Coder CC560 and Proven Capping Technology
To meet these requirements, Almac selected Cap Coder’s CC560 Capping and Re-Torquing system, building on prior positive experience with Cap Coder equipment.
Installed Cap Coder Equipment:
- CC1140 Capper (installed 2015)
- Two CC560 Cappers (installed 2022)
The CC560’s starwheel-based design was a key factor, reducing setup effort and enabling faster, more predictable changeovers. Unlike many competing systems, Cap Coder’s approach separates capping and torquing into dedicated units, delivering greater control and confidence in seal integrity.
Why Cap Coder? Quality, Service, and a Customer-Driven Culture
When evaluating suppliers, Almac’s criteria extended beyond machine specifications.
“Quality, service, and being customer-driven were the main factors. When I visited Cap Coder for SAT, I was impressed by the control of the environment and the calmness of the people.”
That visit proved pivotal.
“The organisation of the facility filled me with confidence in their traceability and quality systems. You can see that the processes are well thought out, and that translates directly into the machines.”
The decision-making process involved multiple stakeholders, including engineering, procurement, and senior leadership, making supplier credibility and long-term partnership essential.
Designed for End Users, Built for Longevity
From the operator’s perspective, usability is everything. Our machines are designed to be intuitive and accessible, so changeovers are faster and teams can get up to speed with ease.
In a regulated pharmaceutical environment, where every second of downtime matters and deviations aren’t an option, this ease of use directly boosts productivity and compliance.
Built to last, our systems are robust, reliable, and engineered to exceed their expected lifespan, giving teams the confidence to focus on what matters most: running their lines smoothly and safely.
Engineering-to-Engineering Collaboration
At Cap Coder, we put the customer first. We communicate clearly, engineer to engineer, and apply our technical expertise to meet requirements quickly and effectively.
This collaborative mindset ensures that every client’s specific packaging needs are fully understood and translated into practical, compliant solutions, never one-size-fits-all machinery.
We focus on being approachable and easy to work with. Building strong relationships with our customers makes a real difference throughout the life of a project.
The Customer Experience
Brandon Ruggiero, Engineering Co-Ordinator, Almac Group
“I chose Cap Coder for their quality, service, and because they’re genuinely customer-driven. From SAT through to installation and ongoing support, the experience has been extremely positive. The robustness of the machines, combined with excellent usability and guaranteed seal integrity, gives us real confidence in our packaging process. Cap Coder don’t just supply equipment, they work with you as an engineering partner.”
Supporting Pharmaceutical Packaging Now and in the Future
With multiple Cap Coder systems installed and a proven track record of performance, Almac continues to rely on Cap Coder technology as their packaging operations evolve.
Industry events such as PPMA USA also play a role in maintaining this relationship, providing opportunities to benchmark technology, exchange insights with peers, and explore future innovations.
We believe in meeting customers face to face, demonstrating our equipment in person, and having direct conversations with the people behind the machines. That openness and accessibility has always been our strength.
More Than Machines: A Partnership Built on Trust
For pharmaceutical manufacturers, achieving consistent capping integrity while maintaining flexibility and efficiency is a complex challenge. Almac Group’s experience demonstrates how a customer-driven engineering approach, combined with robust, validated capping systems, can deliver long-term value well beyond installation.
By prioritising usability, seal integrity, and genuine collaboration, Cap Coder continues to support pharmaceutical packaging teams with equipment they can trust, and people they want to work with.
Ready to partner with Cap Coder? Get in touch with our experts today and let’s make it happen!
Ready to Boost your Productivity?
Get in touch today and one of our friendly sales engineers will be in contact shortly.