Key Strategies for Optimizing Sterile Barrier Packaging

Sterile barrier packaging is the first defense in maintaining medical device integrity and safety. Its necessity and importance can sway medical OEMs to err on the side of caution, choosing a “more is better” approach to packaging to cover all bases.

What often isn’t considered is how over-engineering packaging can unnecessarily drive up costs. With help from an experienced packaging partner, sterile medical packaging can be optimized for superior barrier protection while keeping engineering and expenses in check.

How competing priorities influence sterile barrier packaging

The medical industry is competitive. For many medical OEMs, there’s a sense of urgency in introducing new devices to gain market share. As a result, a common practice is to choose the highest degree of sterile barrier protection and the most durable materials available to facilitate a timely product launch.

A similar choice might be made if an OEM hasn’t fully pinpointed sterile medical packaging characteristics, or doesn’t intend to until post-launch.

Both are workable options for getting medical devices to market safely and quickly, but there could be a tipping point regarding over-engineering costs. Guidance from a trusted medical packaging partner can prove even more valuable in creating exceptional packaging at a price point that aligns with needs and budgets.

Product requirements & sterile medical packaging

Medical devices vary in degree of sophistication, as does the sterile barrier protection required for keeping the devices safe from distribution through point of use.

Packaging materials, performance, usability, and aseptic presentation all contribute to device integrity and patient safety, but how is the right barrier solution determined?

Understanding specific product requirements is essential. Device sensitivity to several environmental factors contributes to an optimum design in sterile barrier packaging, including:

• Moisture resistance
• Oxygen and gas permeability
• Light protection

Likewise, device sterilization needs will impact packaging. Ethylene oxide gas, gamma radiation, and electron beam sterilization methods are aggressive and may even be applied in several cycles. Packaging needs to stand up to the rigors of the process.

A collaborative approach to sterile barrier packaging optimization

The complexities of designing sterile medical packaging could easily lead to over-engineering, either by chance or by choice.

As a world leader in medical packaging, Amcor is both strategic and collaborative in partnering with OEMs to identify appropriate barrier packaging, or customize solutions to meet specific product requirements.

It’s the combination of a willingness to integrate into the medical device OEM’s team and the in-depth expertise in barrier protection that puts Amcor in a class by itself in key areas:

• Streamlined materials selection that combines the appropriate choice and efficient use of barrier films, laminates, and coatings from Amcor’s broad medical device packaging portfolio to optimize barrier protection such as:

  • Amcor Healthcare SureForm™ forming films
  • Standard, Crystal Shield, and High Shield medical laminates

• Efficient packaging design that prioritizes sealing techniques, closures, compatibility, and filling processes to optimize barrier protection without over-engineering individual components. Amcor’s team of design and engineering experts guide the process and can lead customization initiatives as needed

• Rigorous testing and validation focusing on design, sterility, and processes provides in-depth analysis of all aspects of medical device packaging to mitigate risk of failure, validate materials performance and integrity, and ensure top quality barrier protection

• Balancing performance and cost by strategically aligning performance, functionality, and budget considerations to achieve barrier protection that meets exacting specifications. Under the guidance of a packaging expert, removing non-essential materials and weight, for example, can influence production capabilities without introducing risk while reducing waste

• Sustainable solutions are available in some sterile barrier systems that are in line with the growing need and demand for eco-conscious packaging. As a packaging leader, Amcor leaned into sustainability with innovations in recycle-ready films, laminates, and coatings. Further, the Amcor pledge for the planet promises all packaging will be recyclable or reusable by 2025

Imperative protection, important partnership

Optimizing barrier protection in medical packaging must be carefully designed and produced so safe medical devices make it to market quickly without compromising patient welfare. Working with Amcor provides global insights and cost-effective innovations, ready for tomorrow’s challenges today. Learn more in The Insider’s Guide to Sterile Barrier Packaging.