Thermoformed Medical Packaging Lands WorldStar Honors
Prent Corp. has won a WorldStar Award for a custom thermoformed medical package, which is helping one global device manufacturer cut the time needed to deliver life-saving procedures to a hemorrhaging patient.
When it first started work on this postpartum balloon, Prent’s medical device client was looking to create and produce a well-organized product in a package and to cut down on the amount of time required to prepare using the life-saving device. Prent Corp. and designer Julie Isferding worked with the company on a thermoform solution: a tray/retainer combination that would hold various lengths of products, while providing ease of use, offering protection, and aiding in product identification.
This recyclable PETG package requires a pouch application; the retainer keeps the product securely in the tray below and accommodates several lengths of tubing held on top of the retainer prior to use. The engraved graphic logo gives customer identity. Two fold-over hinged flaps secure in a central point to help keep the package compact. The retainer also has an allocated cavity for the tip end of the tubing, which is snapped into place with the tubing coiled around the retainer in its specific cavity then the hinged flaps are folded and snapped into place, securing the product. A formed feature/cut combination at one end of the retainer acts as a removal feature. The form/cut combination at the opposite end of the tray provides an area were the various ends of the tubing can be threaded underneath. These features both allow penetration of sterilization to the product located in the tray below. A perimeter snap ring holds the retainer and provides the track for the tubing to coil around. Two other snap bar features give extra holding power between the tray and retainer. The tray’s return flange helps to avoid contact with the pouch, eliminating abrasion and simplifying loading of the package into the pouch.
According to the designer, the package helps conserve cost. Because the tray/retainer stack combination minimizes the footprint, more product can be shipped in the same amount of space. The tray also saves time needed to use the product to help stop hemorrhages. One assistant can take the components in the retainer and start prepping the saline IV bag while the physician or other assistant is prepping the patient with the components in the tray. In addition, the structure allows for placement of the client’s logo; this helps the company increase brand awareness.
The design of Prent’s compact thermoformed package involves an easy-to-understand tray and retainer that allows multiple medical staff to simultaneously begin using different parts of the device, according to the company. The design allows multiple preparations by the physician and assistants, cutting the time needed to get the device ready and saving valuable seconds needed to stop hemorrhages. While one assistant is starting IV prep using the retainer’s components, a physician is able to simultaneously start another procedure using the tray’s components.
At the core of the package is a retainer whose multi-combination of innovative forms and features is intended to provide cost-savings and enhanced product usability. The new design also allows it to be used as a universal retainer for devices of various length, thus reducing per package costs associated with material purchasing, designing, tool milling, thermoforming, warehousing, and shipping multiple retainers. Because the retainer and tray are stacked, the footprint uses less shelf space than similar products, offering healthcare providers with costs savings and superior product protection and stability, according to the manufacturer. When combined as a whole, retainer features perform multiple functions:
• Allowing fast loading of the product
• Preventing tangle of lengthy tubing.
• Enabling fast and easy access to tray.
• Ensuring excellent sterilization penetration.