Fundamentals of Package Engineering & Design
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1 Fundamentals of Package Engineering & Design
2 Presenters Moderator: Daphne Allen Editor Pharmaceutical & Medical Packaging News Karen Polkinghorne Packaging Engineer & MDM Specialist DuPont Medical & Pharmaceutical Packaging 12/2/2011 STERILE BARRIER SYSTEMS 2
3 Package Engineering & Design Basic functions of medical package Product protection Microbial barrier Physical protection from damage and environment Allow for sterilization Maintain sterility and integrity until use Easy opening and aseptic presentation Identify the product, clearly state information and cautions ASM.org FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 3
4 DuPont Tyvek Properties Feature Benefit Outstanding microbial barrier Sterility maintenance FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 4
5 How Can Tyvek Be Breathable and Provide a Sterile Barrier? FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 5
6 Louis Pasteur s Experiment FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 6
7 Results of Experiment Would the broth Pasteur sterilized in 1863 still be sterile today? On display at Smithsonian years and counting Adequate tortuous paths provide an effective sterile barrier Sterilized packages remain sterile until opened or damaged FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 7
8 DuPont Tyvek Properties Feature Benefit Outstanding microbial barrier Sterility maintenance Sterilization compatibility Broad range of methods; processing flexibility Superior tear strength and puncture resistance Clean peel Reduction in packaging related complaints and recalls Low linting results in reduced risk of device contamination 12/2/2011 FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 8
9 Package Engineering & Design Materials can only perform as intended if used in combination with great design principles Even excellent materials can be sabotaged by poor design FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 9
10 Peel Pouches Design tips Allow ample room between chevron tip and edge of pouch Medical personnel come in all shapes and sizes, design enough room for everyone to get their hands between the chevron and the edge of the pouch Remember, most medical personnel are gloved when opening packages Thumb notches are okay, but proper design is better and costs less FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 10
11 Folding Pouches Not a good idea leads to problems Problem #1 Tents Form abrasion points with carton Scuffing can cause holes in the package FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 11
12 Examples of Issues Caused by Folding Tyvek Film FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 12
13 Microscopic Image of Tent Abrasion FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 13
14 Folding Pouches Problem #2 Sheet Separation False positives during integrity testing Folding can cause sheet separation Explanation of false positives caused by folding ASTM F1929: Dye Penetration Integrity Test video FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 14
15 Tyvek Tough layered product through endless fibers High barrier against micro-organisms FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 15
16 Observed Behavior Relaxed Bending Compression Skin Core Skin Tension Complex Tyvek morphology (bonded skin, unbonded core) dictates complex material model to capture package mechanics FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 16
17 Objectives A: Modest amount of bending B: Severe amount of bending FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 17
18 Folding Pouches Problem #2 Sheet Separation False positives during integrity testing Folding can cause sheet separation False positives caused by folding ASTM F1929: Dye Penetration Integrity Test Examples of internal Tyvek separation due to hard crease or folding of the material FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 18
19 Wicking vs. Channel FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 19
20 Header Bags Design tips Design the opening to be large enough to allow the product to be aseptically presented Easy to fit in the bottom, not so easy to take out of the top Association of perioperative Registered Nurses (AORN) Sets nursing standards and best practices Consider the inner edge of the heat seal as the line separating sterile from non-sterile FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 20
21 Header Bag Example FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 21
22 Header Bag Opening Video FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 22
23 Rigid Thermoformed Trays with Tyvek Lids The ultimate medical package Product protection Aseptic presentation Organization of components Familiar to hospital personnel FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 23
24 Rigid Thermoformed Trays with Tyvek Lids FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 24
25 Example of Delamination / Fiber Tear FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 25
26 Why Is Fiber Tear an Issue? FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 26
27 Rigid Thermoformed Tray with Tyvek Lid Design tips Eliminate fiber tear yes! The Problem the lid is too close to the edge of the tray» Need a clean initiation point to not induce fiber tear» Potential sealant at interface of tray edge and lid The Solution FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 27
28 Three Things Cause Fiber Tear Avoid Them and Make Great Packages 1: Misplacement of the lid during sealing Tray is BLUE / Lid is WHITE Unlikely Fiber Tear Possible Fiber Tear Severe Fiber Tear FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 28
29 Lid Experiment Proper lid placement with overhang 32 out of 32 samples No overhang 26 out of 32 samples FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 29
30 Solution: return flange Eliminates lid placement issues Solution is designed into the tray FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 30
31 Three Things Cause Fiber Tear Avoid Them and Make Great Packages 2. Edge of Tyvek lid, jagged cut FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 31
32 Three Things Cause Fiber Tear Avoid Them and Make Great Packages 3: Over sealed tray FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 32
33 Flexible Form Fill Seal (FFS) Typical Seal Configuration Film Preheat Area Forming Filling FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 33
34 Flexible FFS Seal Skirt Design Forming Sealing Filling Unsealed gap avoids the risk of delamination FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 34
35 Transparentization Occurs when Tyvek fibers receive too much heat, flattening the fibers or even melting the fibers together, more like a film structure How to reduce/eliminate transparentization and spotty seals Trays Add DuPont Teflon sheet to top of heat seal platen to allow for better heat distribution Eliminate any hot spots on the tool, use pyrometer to confirm thermocouples are working properly Check durometer/stiffness of rubber matting material FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 35
36 Too Much Heat for Tray, Not Enough Heat to Activate Heat Seal Coating FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 36
37 Transportation Will your design survive? FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 37
38 Changes in Air Pressure Air pressure inside package vs. outside package Non-breathable materials can t adjust to changes in air pressure Design your packaging to meet the challenges of the distribution environment FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 38
39 If Tyvek pouches get wet, are they still sterile? FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 39
40 Are wet pouches still sterile? It depends. Source Duration Filamentous Fungi FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 40
41 Fire in the OR is the product okay to use? FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 41
42 Fire in the OR where there s fire, there s smoke ISO 11607, The manufacturer shall demonstrate that, under the rigors of distribution, storage, handling and aging, the integrity of the final package is maintained at least for the claimed shelf life of the medical device under storage conditions specified by the manufacturer, as long as the package is undamaged or unopened. FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 42
43 Package Engineering & Design Basic Functions of Medical Package Product protection Microbial barrier Physical protection from damage and environment Allow for sterilization Maintain sterility and integrity until use Easy opening and aseptic presentation Identify the product, clearly state information and cautions Recyclability and sustainability ASM.org FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 43
44 Recyclability and Sustainability FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 44
45 Recyclability of Tyvek Tyvek HDPE is the 2 nd most recycled plastic High volume HDPE end uses Widely recognized by healthcare workers Plastic recycling programs Thermoplastics commingled Monomaterial (HDPE, PP, PET) No paper or metal Compliance is the responsibility of the hospital DuPont is spreading the word... FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 45
46 Healthcare Plastics Recycling Council What is HPRC? Private, technical coalition of industry peers across healthcare, recycling and waste management industries seeking to improve recyclability of plastic products within healthcare. Mission To inspire and enable the healthcare community to implement sustainable, cost-effective recycling solutions for plastic products and materials used in the delivery of healthcare. FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 46
47 FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 47
48 Helpful Reference Documents ANSI/AAMI/ISO :2006 Packaging for terminally sterilized medical devices Part 1: Requirements for materials, sterile barrier systems, and packaging systems ANSI/AAMI/ISO :2006 Packaging for terminally sterilized medical devices Part 2: Validation requirements for forming, sealing and assembly processes AAMI TIR 22:2007 Guidance for ANSI/AAMI/ISO 11607, Packaging for terminally sterilized medical devices Part 1 and Part 2:2006 Order a copy: FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 48
49 DuPont Tyvek in 2012 and Beyond DuPont will be transitioning Tyvek 1073B and Tyvek 1059B to manufacturing lines that use our latest flash-spinning technology to help ensure continuity and flexibility of supply to meet the growing demand for healthcare packaging around the globe. The next DuPont webinar in this series will be focused on the Transition and next steps. Sign up now for this April 2012 event. In the meantime, visit our website for information and frequent updates. FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 49
50 Helpful Reference Documents FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 50
51 Tyvek When What s Inside Matters FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 51
52 Examples of Microbial Challenges Slime mold stack & spore cap E. coli Borrelia burgdorferi Streptococcus Fungal spores Amoebae Bacillus anthracis Pseudomonas Flu Virus Paramecium *Photos from ASM.org Back FUNDAMENTALS OF PACKAGE ENGINEERING & DESIGN 52
53 Q&A Thank you! Thank you for joining today s webcast on Fundamentals of Package Engineering & Design! Contact: Daphne Allen, Editor Pharmaceutical & Medical Packaging News daphne.allen@ubm.com Karen Polkinghorne Packaging Engineer & MDM Specialist DuPont Medical & Pharmaceutical Packaging Karen.Polkinghorne@usa.dupont.com 12/2/2011 STERILE BARRIER SYSTEMS 53
54 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont, The miracles of science, Teflon and Tyvek are trademarks or registered trademarks of E.I. du Pont de Nemours and Company or its affiliates.
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