Case Study: National Bioterrorism Readiness Program

Overview

In response to the heightened concerns surrounding bioterrorism during the anthrax scares, a pharmaceutical packaging client was contracted to prepare a national stockpile of essential prescription medications. This program aimed to ensure rapid distribution of these drugs in the event of an emergency. The client needed to package two specific prescription drugs into sealed bottles labeled with detailed, variable information.

The stakes were high—every bottle had to meet strict labeling requirements, production deadlines were tight, and accuracy was critical to the success of the program. The team that would later become Parlay Data Solutions (PDS) was brought in to address these challenges and deliver a solution that prioritized speed, precision, and reliability.

Challenges

The program presented unique and complex challenges:

Label Complexity

Each prescription label was required to contain several pieces of variable information.

Dual-Functionality Labels

Each label had to include two peel-and-stick label sections, both containing all variable information, to facilitate bottle handling and rapid distribution during emergencies.

Time Sensitivity

The production timeline was extremely tight, often requiring the completed bottles to be ready for distribution in less than two working days from the receipt of bulk medications.

Solution

To address these challenges, PDS implemented an innovative solution tailored to the program’s unique needs:

High-Volume, Custom Label Production

Designed and manufactured "piggyback" labels with two peel-off sections.
Utilized just-in-time variable imaging technology to ensure labels were tailored for each batch with a 24-hour turnaround.

Streamlined Order Management

Deployed a secure web application for order entry, enabling the client to provide detailed order specifications for each production batch quickly and efficiently.

Real-Time Reporting and Tracking

Delivered detailed production reports, including all variable imaging details, to ensure traceability and compliance.

Results

Over the course of the 15-month contract, PDS consistently delivered exceptional results:

Efficiency: Maintained a 24-hour production SLA for variably imaged labels, ensuring rapid turnaround to meet distribution deadlines.

Accuracy: Achieved a 98.7% rate of on-time delivery of label production throughout the program.

Volume: Produced over 18,700 rolls of variably imaged labels, ensuring the readiness of millions of prescription bottles for emergency distribution across the nation.

The success of this program underscored PDS’s ability to deliver high-volume, high-accuracy solutions under strict time constraints. The project not only met the immediate needs of the national bioterrorism readiness initiative but also set a benchmark for future emergency response logistics.

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