The OEM featured four sizes of specialty surgical drapes where the historical foil packaging involved a unique structure. The raw aluminum required for the foil packaging was growing in expense and the OEM had experienced frequent supply chain issues over the last few years. Vonco Products listened, documented
the challenges, explored the desired specifications and dived in to uncover possible alternatives.
THE CLIENT
A leading global manufacturer applying science and innovation to bring to life adhesive-based products for healthcare, consumer, industrial, safety, and other specialty industries.
THE CHALLENGE
The OEM was experiencing supply chain interruptions and sky-rocketing foil costs dueto aluminum tariffs, making it difficult to get their specialty surgical drapes to healthcare clients. Being a long-established product line, the packaging specifications had been set in stone many years ago. The primary packaging goals had been centered around OTR and MVTR barrier properties and proposed shelf-life. The OEM had defaulted to foil due to its high barrier qualities. Packaging specifications were dated and had not been reviewed since inception. Were they still realistic or just an original assumption?
THE SOLUTION
The OEM reached out to ISO 13485 certified Vonco, whose team of custom flexible packaging engineers dove in immediately, asking the right questions to challenge the system and review the truly necessary specifications around packaging structure, including thickness, barrier properties, puncture resistance, shelf-life, printing, and traceability. The original specifications were reviewed in detail, as well as the actual intended use and average time on shelf to see if desired physical properties could be met with alternative structures and materials.
With expertise in foil alternatives, Vonco identified packaging options that mitigated risks and helped the OEM remain competitive. Vonco also connected the OEM with additional raw material vendors that could help achieve cost-savings, while meeting ideal barrier specifications and keeping supply chain woes at bay. Additionally, Vonco provided information on high-speed processing solutions that could dial in the structure even more and improve manufacturing efficiencies with increased output.
THE RESULTS
Vonco has never been one to not shy away from a challenge and helped outline a validation timeline and the roadmap to commercialization for the client to convert the entire surgical dressing line. The OEM has the potential to save $436,750 annually but is in the process of reviewing if the re-validation efforts are worth the cost-savings. Vonco continues to help additional medical device, diagnostic, and pharmaceutical clients make the switch to foil alternatives.