Case Study: Packaging Solution for a Heavy Medical Device (30 lbs)
Background
Averra Packaging was approached by a medical device manufacturer with a unique problem: protecting a medical device that weighed almost 30 lbs. The solution needed to ensure product safety, be cost effective, require minimal warehouse storage space and reduce environmental and shipping impacts. Given the weight, fragility and high value of the units, the packaging also had to pass the rigorous FedEx drop test requirements, specifically meeting the standards of ISTA-6-FedEx-A, ISTA-6-FedEx-B, and ISTA 3B Multiple types of packaging were considered, and Averra Packaging worked quickly to show that a thermoformed RHDPE end cap is the right solution for this unique packaging problem.
Solution
Given the customer parameters and cost considerations, Averra Packaging developed two RHDPE thermoformed end caps as our proposed solution. We developed models and samples which the customer was able to test against the drop test requirements. We were able to create sample parts that passed all testing on the first round. As a result of our expediency, effective design, superior nesting, reduced warehouse space requirements, transport/ shipping costs, total environmental impacts and unit pricing, Averra Packaging’s solution was the clear winner vs. the other materials and designs being considered.
Conclusion
There are distinct and real advantages to thermoformed fragility packaging/ end caps over corrugate, EPS & molded pulp. Below is a table which shows some of the environmental impacts of a thermoformed part vs. other commonly considered solutions. Averra’s thermoformed HDPE packaging proved to be the right solution for protecting this heavy, fragile, and expensive medical device.
Data Summary*
*Data provided by OpenLCA. For more information, please click here to view the full white paper, or contact us.
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