This article has been contributed by Deepak Kumar Aggarwal, Senior Manager at PwC.
When we pick a colorful blister pack or Vial to take our dose of medicine we think of the meticulously manufactured, packed product tested by qualified clinicians behind it. Well, this is true, but a complex well-orchestrated system, using intelligent algorithms, sensors, robotic arms, scanners, and Radio-Frequency Identification (RFIDs) devices are deployed warping this lifesaving drug into a form that reaches us. Application of Artificial intelligent algorithms, IoT, and connected sensors are transforming packaging of each pill, vial, or injectors to ensure the medication we are taking is authentic and packed with precise specification like an unbreakable promise.
The application and acceptance of AI technologies is rising rapidly. We have heard many success stories across multiple industries as well. Similarly, throughout the value chain of pharmaceuticals Industry these innovations are assisting technicians to improve underlying intricate processes. These automated processes are under constant monitoring via intelligent IoT sensors. The predictive analytics capabilities generate demand at subprocess level and help plan resources in time.
With the latest technology adoption, Patients and Providers can be confident that a well-tested, documented and authentic product is dispensed to you after meeting all the rules and regulations. All Small, Medium or Large corporations are striving hard to manage this fast change.
Let’s examine few focus areas which will continue to see dynamic shifts in this industry.
Quality Control Systems
If any faulty drug or expired package enters the supply chain, then it directly erodes the confidence of patient and provider. The use of AI enabled quality control systems facilitates automatic label verification and inspection. The monitoring of labels, seals and instruction detects any subtle defects. These systems check the correct drug name, dosage information, regulatory symbols, etc. These also check for any misprints, missing datapoints, and translations.
Complex packaging like pre-filled syringe and autoinjectors greatly benefited with improved accuracy. High resolution AI driven cameras inspect the needles for any bent, burr, or damage. Enhanced imaging systems check correct drug fill volumes in bottles and pre-filled syringes. It also detects any abnormality such as air bubbles or unexpected color/density changes. Overall, it reduces the cost of human error and ensures that highest level of regulatory norms is met. For any brand these are the primary factors that can damage brand value overnight. These measures have resulted in fewer product recalls, safer distribution channels, and increased consumer trust.
Anti-Counterfeiting and Traceability
Counterfeit pharmaceuticals continue to pose substantial global risks. Pharma manufactures, distributors, and pharmacies have collaborated to fight counterfeiting. The combination of AI and block chain enabled systems coupled with IoT devices at supply chains nodes has proved to be very effective. Machine vision coupled with AI algorithms verifies the Package authenticity by checking micro prints, holograms and serialization codes. Any anomalies in data matrix/ QR code triggers risk of counterfeiting. Continuous data driven feedback by using Predictive AI fags “suspicious movement”.
The integration of AI with blockchain and the Internet of Things (IoT) offers comprehensive traceability across the entire supply chain. Technologies such as smart barcodes, RFID, and unique digital identifiers — analyzed by AI — enable end-to-end tracking from production to point-of-sale, swiftly detecting anomalies and verifying authenticity. Even at the time when a pharmacist is dispensing the drug, AI driven scanners can authenticate serialized packs, reducing the risk of counterfeit drugs. Employing advanced monitoring devices further reduces the risk of tempered or contaminated products to reach unsuspected patients/providers.
Ashwini
Supply Chain Planning
In the process intensive industry where accuracy is very crucial, managing the dynamic demands, supply and inventory level across supply chain is crucial for continuous market penetration and cost saving. AI’s capacity to process extensive datasets — from historical sales figures to real-time epidemiological trends — enables accurate demand forecasting, inventory management, and resource allocation. Traditional Supply chain solutions within traditional (Enterprise resource Planning (ERP) system and specialized Cloud solutions in Supply chain planning are using Predictive AI models. Effective demand and supply planning results in lower waste, minimized shortages, and enhanced responsiveness to meet evolving healthcare demands.
Furthermore, AI-based predictive maintenance utilizing machine sensors helps prevent equipment failures, minimizes operational disruptions, and maintains high standards of safety and efficiency.
Subham Kumar
Personalized Packaging Solutions
A new demand era of customized pharmaceutical packaging tailored to individual dosages or specific patient needs is becoming more acceptable. AI driven packaging lines creates customized blister packs or pouches labeled with patient specific dosage schedule (morning – 20 mg, evening – 10 Mg etc.). Such intelligent packaging solutions enhance both product security and patient interaction, contributing positively to patient adherence and outcomes. Other IT solutions to accommodate various disabilities and the integration of digital medication reminders is also evolving.
Sustainability Initiatives
The pharmaceutical sector is also actively pursuing its sustainability goals. Monitoring energy use in warehouses by AI models and by using smart switches it reduces overall carbon emission. AI simulations are Identifying environmentally responsible materials proposing alternate biodegradable packaging materials. Large corporations have been funded and experimenting with technologies in many ways. At the same time Small and Medium Enterprises (SMEs) are facing challenges and competing for resources. They fully understand that AI-driven packaging technologies, supply chain optimization and control systems offer considerable benefits, but they face specific barriers to earlier adoption.
In the capital-intensive industry getting the best Returns on Investment (ROI) is where executives at SMEs would like to focus so that they can justify further investment. SMEs should approach investments strategically and can take cues from below framework. Industry experts widely anticipate that as specialized skills become more accessible and hardware availability increases, the cost of emerging technologies will decline. This shift will enable all organizations to justify their investment more effectively to bring benefits to
Outlook
We must be cautiously optimistic as AI technology continues to evolve, pharmaceutical manufacturing, packaging and logistics will become increasingly sophisticated. The secure and responsible use of AI is on agenda for most regulatory bogies across geographies.
As we stand at the crossroads of intelligent machines and human skills, we are reminded by experience that humanity has greatly benefited from technological advancement. By bracing these principles with care and responsibility, we can significantly advance the pharmaceutical sector, ultimately benefiting the society as a whole.
Subham Kumar
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