Plastics packaging: versatile thermoformed clamshell nabs award

One of MPW's recently named Notable Processors, customer thermoformer Prent Corp. (Janesville, WI), has been recognized again, this time winning an AmeriStar Award from the IoPP (Institute of Packaging Professionals) for its "universal package." The new clamshell package is designed to help its medical device customers pack up to 35 different SKUs. Costs are saved on tooling, per-package costs, and assembly costs.

Prent's package was the only winner in the Medical Device category for this year's AmeriStarAwards. The package works for Prent's customer, an unidentified medical device manufacturer, to accommodate both old and new devices, including those with different handles, triggers and product configurations.

Tooling costs have been reduced because the package is designed to be thermoformed using just one tool rather than separate tools for a tray and retainer. Cost per package is said to be reduced by more than 25%, again because there's just one thermoformed clamshell tray—rather than a tray and retainer. Also, the device manufacturer requires less assembly time since the one-piece thermoformed clamshell can be loaded faster.

The one piece design—coupled with four undercut features inside the circular cavity—has improved the ease and control of loading and unloading the spiral medical devices. The undercuts also are said to reduce product damage and prevent the medical device from popping out of the package or out of the operating room's sterile field

As we reported here, Prent late last year opened its first facility in Europe, primarily to handle thermoforming of packaging for medical devices, and also doubled the size of its existing facility in China.