Packaging is normally thought of as a cost. Leading surgical instrument maker, Linvatec reverse engineered a package design that reduced material costs by about 16 percent, and increased manufacturing capacity by approximately 15 percent. This cost-effective packaging was the result of work by the package consolidation experts at Perfecseal using Eastar™ 6763 copolyester produced by Eastman Chemical Company.

Linvatec wanted a new package that would consolidate five existing designs down to one. It had to maintain the same footprint - as well as use existing seal equipment – a challenge for even the most innovative designer. Eastar™ 6763 copolyester was the material of choice because of its proven track record for strength, clarity, and processability.

“Linvatec has always had such good results with Eastar™ 6763 copolyester, that we did not consider using anything else for this application. Plus, our thermoformers find it easy to process,” said Linvatec Senior Packaging Engineer Tara Martin. The final design included two thermoforms: 1) an inner protective clamshell for the blades only and 2) an outer tray, which also housed the burs. This inner clamshell was formed with a more intricate interlocking grid pattern for additional stability of the blade during shipping. The new package’s streamlined, user-friendly design is 25 percent smaller than the previous outer carton, providing additional savings in shipping and storage.

Eastar™ 6763 copolyester passed rigorous shipping tests and gamma sterilization, while maintaining pristine clarity. “We were absolutely confident in Eastar™ copolyester’s ability to maintain package integrity for the shelf life of the product,” said Martin. ‘It’s not enough to supply a good material. The technical know-how is equally as important in helping processors produce challenging designs while meeting today’s aggressive deadlines,” said Eastman's medical market manager.