4 Innovative Strategies for Lowering Medical Device Packaging Costs

Medical device development is expensive. Taking a Class III product from concept through premarket approval total approximately $113 million.¹

It stands to reason, then, that investing in the most protective, most functional packaging for a multi-million dollar device seems logical. After all, there’s a lot at stake monetarily and in terms of safety and performance.

However, over-designed packaging can be overkill — and that negatively impacts the bottom line. Even if medical device packaging costs seem relatively small in comparison to the device itself, don’t overlook opportunities to save money. Start with these 4 innovative strategies.

1. Identify Design Efficiencies

An objective assessment of medical packaging design by an experienced packaging supplier may reveal areas of immediate improvement.

Can certain features be simplified or eliminated? Will a different sterilization or sealing process accomplish the same results? Could a different material be used without impacting performance?

Collaborating with a packaging expert to find answers to these types of questions could mean savings in both the near- and long-term.

2. Weigh the Impact of Down Gauging

Down gauging packaging provides a dual benefit: Reducing film thickness reduces the weight and possibly the cost of the package, without compromising medical device integrity. It also helps address environmental concerns. More sustainable packaging that meets minimal operational thickness simply has less material to introduce into a manufacturer’s waste stream and promotes a circular economy.

Depending on the packaging supplier, there may be additional cost savings realized with regard to sustainability. Amcor’s global reach means we have an acute awareness of the many differing sustainability initiatives and regulations throughout the world. Having insights into what current legislation dictates in various regions helps inform decisions about materials that align with requirements — saving time and cost upfront, and in the prevention of penalties, distribution delays, and rework.

3. Reconsider Materials

The complexities of medical device packaging can challenge conventional solutions. Finding alternate materials requires an understanding of the composition, compatibility, and runnability of lidding and forming materials. Leveraging the technical expertise of a packaging partner is essential for accuracy and could save the time and cost of experimentation.

The Amcor Technical Services Optimization (TOS) team has nearly four decades of combined technical packaging experience, including focused expertise in medical device packaging. This depth of knowledge has earned Amcor the trust of medical manufacturers, as has
our commitment to packaging innovation.

New materials formulations, applications, and solutions are routinely integrated into the Amcor products portfolio. As a result, Amcor is uniquely positioned to recommend alternative materials that may improve medical packaging performance without substantially affecting cost.

4. Leverage Packaging Supplier Competencies

Often, operational efficiencies and next-level medical packaging excellence are the result of existing challenges or heightened industry and consumer expectations around certain issues. Staying ahead of the curve while managing medical device packaging costs can be tricky.

Amcor helps manufacturers target opportunities for meaningful, affordable packaging solutions using proprietary processes and tools:

Catalyst™ from Amcor

Catalyst™ from Amcor fuels creative collaboration in medical packaging design. The process and team are driven by insights, creativity, and engineering to arrive at viable solutions quickly.

Time and costs are efficiently managed at the earliest stages of packaging design because Catalyst™ provides the tools and resources to:

• Understand the challenges more deeply by asking the right questions to determine the factors behind packaging decisions that may be impractical or inefficient
• Create meaningful ideas more quickly by applying the capabilities and assets that address the challenges
• Deliver better packaging strategies and solutions through real-world prototyping and testing

Amcor ASSET™ Life Cycle Assessment

The Amcor ASSET™ life cycle assessment uses a Carbon Trust-certified toolkit to understand and compare the environmental impact of packaging. The data-driven tool provides objectivity around each stage of a material’s life cycle and details how manufacturers may have a choice in recyclability and carbon footprint reduction.

Using the ASSET™ tool provides a tailored snapshot of packaging options that support informed decisions about more sustainable solutions for more seamless implementation and faster time to market.

Broadest Packaging Solutions Throughout Product Life Cycle

Amcor offers a breadth of packaging solutions that provide continuous cost reduction opportunities throughout the product life cycle, including:

• Initial prototyping: Amcor offers rapid packaging prototyping and sampling capabilities to finalize the ideal packaging design
• Production ramp-up: Amcor’s wide selection of pouch, bag, tray, and lid products handle a variety of applications when production is manual or starting to ramp-up
• Steady state high volume production and automation: Amcor form, fill, and seal products optimize productivity and cost

SOURCES
¹Ethide Laboratories, How Much Does Medical Device Development Cost?, Undated