Getting an Edge

Ongoing problems nag engineers for solutions. During his presentation at MD&M Minneapolis 2007, Jason Crosby heard about one such problem from an attendee: “How do you prevent pinholes or punctures when placing trays into pouches?”

When he got back to his plant (Plastic Ingenuity; Cross Plains, WI), the medical business manager started researching potential solutions. He found a tray his company had made for a crayon promotional giveaway fashioned with a smooth edge. “We had patented technology for creating a round edge trimmed on the inside,” says Crosby. “It was originally designed to be aesthetically pleasing, but it is also functional.”

Pinholes and punctures can result when thermoformed trays “creep” or shift inside pouches, causing flange edges to rub into the pouch material. Many of today’s pouch films are intended to resist punctures or pinholes, but these breaches can still occur when sharp tray edges rub into pouches during transport or handling. Carefully designed double barriers may not remain double.

Sharp tray edges have also been associated with nurse complaints of glove punctures as they reach for trays in the surgical suite.

Crosby says that once presented with the rounded tray edge idea, his team of engineers set out to tailor the design for the medical industry. “It took us a fair amount of time to perfect this process,” he reports. Plastic Ingenuity had built special machinery that thermoforms a vertical flange that is then trimmed on the inside of the tray’s outermost formed features.

To create its new SafeEdge medical trays, Crosby and his team identified a standard footprint for medical applications: 9.5 x 7 in. in its outer dimension. Insert molds can be used to customize tray interior design. The new flanges are sufficient for typically used sealing operations.

Plastic Ingenuity is working on other standard outer dimensions for smaller products as well as for slightly larger ones. The company is asking for industry feedback on such dimensions. Custom tool-building services are also available.

Crosby adds that SafeEdge trays offer an easy-grip feature on the underside.

The new trays will sit a little higher when nested, so packaging density may drop a little in bulk shipments to medical device manufacturers, Crosby says.

There is a cost associated with the new technology, and medical device manufacturers will have to validate and document any packaging or process changes. Crosby believes that any added costs and efforts are worth it, given the increased safety and unique look.

The medical device manufacturing industry is trying to drive costs out of several processes these days, including packaging. Paying extra for premium designs may not be possible for some budget-conscious companies.

However, responding to problems that nag industry—as well as nurses or other healthcare practitioners—can benefit both manufacturers and end-users. Manufacturers may find the additional expense and effort worth it to gain a competitive edge.

Daphne Allen
Editor