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MedTech Outlook | Sunday, April 19, 2020
Medical device developers can get their devices to market more quickly and at a lower cost if they regard packaging as an integral aspect of the product rather than an afterthought.
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and including it early in the development process, developers may ease stress, limit risk, create a more successful product, and avoid costly surprises.
It is vital to maintain focus on end goals throughout the design process. Packaging design has an impact on shipping, sterilization, and end-user experience. Weighing and ranking all of the components into a sterile device's package might be difficult. However, by establishing the sterilization method early in the design phase and collaborating with a packaging and sterilization vendor concurrently, medical device manufacturers can limit risk, optimize outcomes, and avoid expensive surprises. They can proceed with the process confident that the eventual packing will maintain the device's sterility while optimizing available space. The packing of medical devices varies depending on the type of sterilization that the equipment will undergo. For instance, ethylene oxide (EO) sterilization requires a permeable packing material such as Tyvek to allow the EO gas to enter and exit quickly. Gamma and e-beam sterilizing procedures require packing layouts that are slightly different. Instruments that have been steam sterilized are often wrapped in special disposable paper with printed stripes that change color when exposed to steam temperatures.
A thorough understanding of these distinctions can help developers save significant time and money. Without doing so, a company that picks one sterilization technique may discover much later in the process that the selected method will not function with the device, forcing the company to rethink its packaging to use another method of sterilization. Regardless of sterilization, all pouches or lids must completely seal the device within the package to ensure that no fungus, mold, yeast, virus, or bacteria enter the product during normal handling following sterilization. The size of the container can have a significant impact on the cost of sterilization—and thus on the total development budget. Contract sterilizers work within the confines of predetermined chambers. As a result, packaging that adheres to these limits maximizes the amount of product that fits into each sterilization run and lowers the cost per product of sterilization. For instance, even an additional two inches of chamber space results in underutilized space, increasing expense. This is particularly critical when working with smaller chambers, as the amount of product that can fit inside the chamber varies significantly depending on the package dimensions. Collaborating with the sterilizing vendor upfront can assist developers in designing packaging that maximizes space use. If packing can be made smaller, the sterilization chamber can hold more product. As a result, sterilizing costs per device are lowered.
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