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A medical device manufacturer lowered the per-unit cost of protective packaging by 20% and increased productivity by more than 30% by switching from polyethylene (PE) die-cut foam inserts to a polyurethane foam-in-place system, says packaging supplier Storopack. Headquartered in Metzingen, Germany, with fabrication centers throughout North America, Storopack offers design and manufacturing of FOAMplus protective packaging systems and an array of associated services.

PlasticsToday Staff

December 12, 2013

2 Min Read
Polyurethane foam-in-place packaging reduces cost, boosts productivity for medical manufacturer

A medical device manufacturer lowered the per-unit cost of protective packaging by 20% and increased productivity by more than 30% by switching from polyethylene (PE) die-cut foam inserts to a polyurethane foam-in-place system, says packaging supplier Storopack. Headquartered in Metzingen, Germany, with fabrication centers throughout North America, Storopack offers design and manufacturing of FOAMplus protective packaging systems and an array of associated services.

Storopack_MoldedParts-250.jpgStoropack typically provides its customers with FOAMplus premolding services that include an initial analysis and consultations. This process led to the development of a ready-made universal packaging system for one of the US medical device manufacturer's product lines. Foam cushions protect every model of the product line using a single carton size, contributing to the aforementioned cost and productivity benefits.

The delicate medical device consists of two parts, including a screen with integrated computer unit. The company had been using PE die cut foam inserts, which were both costly and laborious to assemble, according to Storopack. As an alternative, the Storopack Design Center developed a three-component engineered foam-in-place packaging design. The bottom pad accommodates the screen unit, and the second part is inserted in the side pieces. The protective packaging is designed to prevent assembly errors: the side pieces fit into the bottom pad, which is positioned in the center of the carton. The interlocking elements fit the various models while providing sufficient support to secure each item in place.

Rather than setting up the molding tool and FOAMplus machine system on site, the manufacturer chose to have the cartons and molded parts produced at the Storopack fabrication center in Atlanta. The packaging is then sent to the device company, where individual shipments can be processed in two to three minutes.

Storopack's design center develops custom protective packaging systems and performs a number of tests to ensure delivery of a flawless product. Customers can opt for a just-in-time packaging delivery program or have the manufacturing equipment installed on their premises.

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