There are numerous factors to consider in packaging; some obvious, some not so obvious.

No matter what type of device a medical company might manufacture, chances are that the product will need to be packaged. This packaging must serve an array of functions, from delivering product protection to enhancing both the product's visibility and the company’s corporate image. The packaging may have to meet some unique application-specific needs as well, depending on where and how the device will be used, such as sterile transport or damage protection. Design turnaround and manufacturing of the packaging also needs to be timely and fit the constraints of a finite budget.

How then does a company create a package that’s a perfect fit for its medical device? It comes down to selecting the ideal medical packaging partner. The following five points can guide medical device manufacturers towards the packaging company that is right for them.

1. One-stop shopping. Choose a packaging company with numerous materials and capabilities under one roof.

The best results can be gained from working with a packaging company that can handle the entire life cycle of a medical package in-house. This includes product definition, initial solid-model design and prototyping, to tooling and short-run or long-run manufacturing. Keeping all aspects of the process in-house allows for maximum control of both the design and the package quality.

A packaging company should have a wide range of materials at its fingertips. Seek out a company that works with an array of plastics, foams, fibers, and other materials, and has the expertise to choose the best material, or combination of materials, for a product. The company should recognize that all rigid plastics are not the same and the option to work with either glycol-modified polyethylene terephthalate (PETG—common for all medical packagers because of its ability to withstand gamma radiation), polyvinyl chloride (PVC), or polycarbonate plastics is a huge plus. Some packaging manufacturers are working with polyurethane films, which are rugged and durable and also flexible enough to accommodate sleek designs and pouches. Niche-specific packaging vendors may also offer a variety of foam types, including cross-linked polyethylene and polypropylenes.

Finding the optimum packaging solution requires a very specific or combination of manufacturing processes—so look for a company that demonstrates a broad range of flexible conversion capabilities, including vacuum-forming, compression-molding, and cleanroom manufacturing. Medical devices have diverse packaging needs, so certain conversion processes may be more suitable for a given product. By using CNC routing, a company can make customized trays or case inserts for protection and organization of surgical instruments. Packaging companies that work with laminates can offer products that combine benefits in the medical market, such as cushioning with breathe-ability. The packaging supplier should also possess a range of capabilities and processes that include skiving, slitting, die-cutting, thermoforming, compression molding, and heat-sealing.

Our company recently developed packaging for delicate orthopedic implants. A thermoformed plastic blister was used as outer protection, and then a piece of compression-molded foam was nestled inside, securing the implant within the package and preventing cracking of the tray during transport. The entire package was created at on-site cleanroom facilities, enabling the medical device manufacturer to sterilize the entire product without compromising it.

2. Partnership. Choose an efficient company with expertise willing to work as a team every step of the way.

Choose a company with extensive medical packaging experience—one with a history of producing results for medical device companies. It’s not always essential to work with a large company, but it can have its advantages. A larger company may be able to utilize its purchasing power and get better pricing on materials. Also, a company with a range of geographic locations can help produce large volumes and ship quickly when necessary.