One of our most frequent manufacturing projects, thanks in large part due to their diversity and wide range of potential uses across several industries, are blister packs.

Regardless of whether you need a crash course in why blister packs might be the best option for your needs or want to know what sets Janco’s process apart, you’ll find answers below.

Here’s what we’re covering:

• Types of Blister Packs
• Common Industry Uses
• Blister Pack Benefits
• Blister Pack Materials
• Janco’s Custom Thermoforming Process
• Why Janco?

Types of Blister Packs

Ever wonder why you’d go with a traditional blister pack VS clamshell packaging?

Trying to figure out what type of blister pack is the right fit for your needs depends on several variables, from the product you’re packaging to the quantity that you need to manufacture.

While there are a ton of similarities in terms of benefits, there are also some essential differences that make each type of blister pack ideal for specific product needs. Here’s a quick breakdown of what sets different models apart.

Clamshell: Most variations of blister packs use a cardboard backing, but a clamshell package is a bit different. Instead, two plastic pieces are hinged together in the thermoforming process, either at the side or at the base. This comes in handy in a variety of different ways, allowing clamshell packaging to stand upright on shelves when stocked in stores.

Our custom design process gives you the freedom to ensure the clamshell is aligned with your distinct needs, so the plastic may be heat-sealed closed on both ends or have a button to snap one side open and shut.

Most commonly, clamshells are used for sets that have more than one part, such as tool sets with several nuts and bolts or toy sets with multiple small parts. Generally, this type of packaging gives your product the same level of protection as any other blister packaging but works best for products that require more of a unique approach or need to be re-sealed after use.

Face Seal Blister Packs: This is what would be considered a traditional blister pack, where the plastic blister is designed and manufactured to fit your product (or several products) and then heat-sealed to a cardboard backing. This is ideal for packaging items made in large quantities because it’s fairly inexpensive compared to other options.

Trapped Blister Packs: This is the most similar to the traditional blister pack, but there are a few key differences. With a trapped blister, the name says it all – your plastic will be trapped between two pieces of cardboard. In addition to the usual cardboard backing, another piece is added over the front to cover the shape of your product using our custom die-cutting process. Because this doesn’t require blister pack heat-sealing methods, trapped blister packaging it’s generally a cheaper option.

Full-Face Seal Blister Packs: In another variation of the classic blister pack, the plastic surrounds both the product as well as the cardboard backing that supports it. Depending on your unique design needs, the plastic is heat-sealed to the card or slid through additional plastic pieces on each side. A full-face seal blister is typically used to enforce the strength of the blister pack packaging.

Full Card Blister Packs: Similar to a full-face seal blister, the plastic on a full card blister is manufactured to cover the entirety of the cardboard backing. Instead of using the typical heat-sealing process, this uses flanges that wrap around to seal the plastic.

Need help selecting the right type of blister pack for your packaging needs? We’ll provide the guidance you need.

Get in touch

Common Industry Uses for Blister Packs

Our team has served a wide range of industries over the years, offering custom solutions with the quality and precision that you depend on.

Even within each industry, there are multiple potential uses for blister packs. Below are some of the common uses we design and manufacture blister packs for in-house, but if the item you’re thinking of isn’t on the list, reach out! Our job is to find a solution.

Medical Industry Blister Pack Uses:

• Medical devices
• Medical implants
• Medical and surgical instrumentation

Commercial and Industrial Blister Pack Uses:

• Electronic devices and accessories
• Automotive component packaging
• Oral health products including toothbrushes and dental floss
• Batteries
• Screws, nails, nuts, and bolts
• Protective cases
• Ink cartridges

Blister Pack Benefits

Packaging your product can be as crucial as the manufacturing of your product itself. Packaging can determine a lot of variables, from how attractive your product looks on a store shelf to how protected your product is against wear and tear.

These are some key benefits to choosing a blister pack:

• Protection – Not only do blister packs offer a high degree of protection during both transportation and storage, but you can also increase protection depending on the exact model and design that you choose.
• Lightweight build – The lightweight design is great for handling, and it also means that you’ll benefit from lower transport costs, especially if you’re manufacturing and shipping large quantities of your product.
• Unique design – The unique and wide-ranging design possibilities with blister packs mean that we can adjust the packaging to your exact needs. Our team offers direct consulting to help ensure we’re adding value to your packaging.
• Easily recycled – In addition to so many practical benefits, blister packaging is also easily recyclable, so you can feel good about your packaging choices.

Blister Pack Materials

Our team can help with material selection based on the unique requirements of your packaging needs. In general, blister packaging is comprised of PET, PETG (polyethylene terephthalate), HIP (high impact polystyrene), or PVC (polyvinyl chloride) plastic.

Our engineering team can help you select the best materials for desired properties including:

• Biocompatibility
• Anti-static
• Fire-retardancy
• Impact
• Abrasion resistance

How Blister Packs are Made

Blister packs are manufactured using our custom thermoforming process. Thermoforming involves taking a plain plastic foil (either PET, PETG, HIP, or PVC, as mentioned above) and transforms it into a three-dimensional shape by applying heat and air pressure. The plastic is molded into whatever shape is needed to bring your packaging solution to life.

Valued for being both highly customizable and cost-effective, custom plastic thermoforming at Janco allows us to manufacture single-use plastic parts with a wide range of potential uses. We frequently thermoform plastic in a variety of colors, densities, and thicknesses.

Our team also has trusted industry partners who offer injection molding services, which offer slightly different capabilities. Reach out to us directly to learn more.

Work with Janco for Your Blister Packaging Contract Manufacturing

Our team has been trusted as the go-to for quality contract manufacturing solutions for over six decades.
From the very beginning, it has been our mission to make the manufacturing process easy for you, with a team that has the experience to answer your questions and provide creative solutions for custom packaging needs.

With cutting-edge technology, an expert team of engineers and project managers, and a comprehensive quality assurance process, our team is proud to offer competitive pricing and unbeatable customer service.

Ready to manufacture custom blister packaging aligned with your unique product needs?

Reach out to Janco for the guidance and experience you need to get the job done right.

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The CapSure Sterile Barrier Packaging System delivers exceptional performance and economic efficiency. The packaging system reduces waste and optimizes the supply chain while the design ensures the orthopedic implant is protected.

“We at Guardian were happy to include our partner Janco in the AmeriStar award as a contributor to our CapSure Sterile Barrier Packaging System,” said Tracy Momany, President and CEO, Guardian Medical USA. “We envisioned a single PETG tray, capable of securing all of the different implant sizes in a family of medical devices, within our CapSure tube packaging. Janco turned this challenging concept into a functional, and award winning, reality.”

Janco is proud to have played a part in the medical manufacturing and design of this award-winning packaging. When Guardian Medical presented the design concept to Janco, the design team worked with Guardian to develop the tray and how it would work within the parameters of the larger design.

Janco continues to manufacture the PETG tray using our thermoforming technology inside Janco’s ISO-certified clean rooms.

About the Ameristar Award

The AmeriStar Awards Competition recognizes the best in professional packaging design solutions. The contest sets high criteria and looks for distinct features and advantages that deliver tangible value. Hosted and judged by a distinguished jury of packaging professionals and industry experts, Guardian Medical’s CapSure Sterile Barrier Packaging System stood out as an exemplary example of innovation in the medical device packaging field.

Janco’s Medical Packaging Capabilities

Guardian Medical is just one of a number of customers Janco works with on packaging design and manufacturing. With decades of experience in the field, Janco is synonymous with quality and consistency. We offer a number of capabilities, including thermoforming, medical device assembly, medical laminating and clean room manufacturing.

Want to learn more about how Janco can meet your medical device packaging needs? Reach out today.

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For our 60th anniversary, we wanted to highlight a bit about our history and what makes Janco different.

Part of N.H.’s manufacturing history

Janco, Inc. is based in Rollinsford, N.H., located just 90 minutes north of Boston and the major biotech and industrial manufacturing hubs within the surrounding communities. This small town has a long manufacturing tradition, beginning in 1820 with hydro-powered mills built on the Salmon Falls River. These early manufacturing facilities produced wool textiles and later cotton goods.

Manufacturing of textiles in Rollinsford continued into the 20th century and today these brick mill spaces are used by artists and traditional artisans who produce furniture, paintings, and other goods on a small scale.

In addition to the historic mills, Rollinsford also became the home of modern advanced manufacturing facilities in the 20th century, including Janco, which set up shop on its campus on Goodwin Road. It quickly became part of a larger community of advanced manufacturing companies located throughout Southern N.H. and the greater Boston region.

The beginning of Janco, Inc.

Janco was born in George Janetos’ barn in Rollinsford. At the time, George worked at a local contract manufacturer, Spaulding Fiber, which specialized in the use of fiberboard in sporting goods equipment. When George got home, he would head to the barn and experiment with polyethylene plastic resin. He took his experience and the results of those experiments and opened Janco in 1963 with his brothers Paul, Louis and Andrew. The company quickly made its mark with innovations that revolutionized the industry.

Janco was originally focused on industrial applications and developing athletic equipment. Decades later, Andrew saw a market for medical trays, packaging services and medical device assembly in certified cleanrooms. In 1985 Andrew installed the first cleanroom, launching the medical side of the business. It also made Janco the first company to produce thermoformed medical trays inside of a class 8 cleanroom.

Janco, Inc. today

Today, Janco operates a 100,000-square-foot facility that includes seven FDA-registered and ISO-certified clean rooms. The company produces high-quality and cost-effective thermoforming and compression-molded services for both medical and industrial markets, from industry leaders to start ups. All products are made in the U.S., with service available around the globe.

Janco has class 7 and class 8 ISO certified cleanrooms available for use in manufacturing, assembly and packaging services. We also have an extensive range of forming and fabricating capabilities, including laminating and compression molding of plastics and foam for a wide range of applications.

“We owe much of our success to our skilled Janco team,” said President and CEO Mark P. Janetos. “Whatever the project, they go above and beyond to deliver creative, cost-effective solutions. You not only get a skilled vendor, but a partner you can trust every step of the way.”

Want to know more about our capabilities? View our full list of industrial and medical services.

What makes Janco, Inc. different?

Customized service is at the heart of what we do. We base the”Janco Difference” on three C’s:

1. Caring – Every project is different and has specific needs. It’s why we take a customized approach to every project, taking time to answer your questions, offer unique solutions, and ensure you understand every step of the process. We believe long-lasting relationships with our customers take a high level of care.
2. Comprehensive – From design to delivery, we offer expertise and state-of-the-art technology. We’ve designed a thorough quality assurance process that ensures your products are precise, reliable, and completed with comprehensive attention to detail.
3. Competitive – Our customers expect high-quality and cost-effective execution. Our competitive solutions and unbeatable quality are part of what makes us unique

Conclusion

It takes expertise, business insight and dedication to withstand the ups and downs of 60 years in business. Janco, Inc. has earned its longevity, in part, due to its experienced staff, high-quality products and exceptional service. Whether you need a customized product solution or are working with distinct specifications that require precision, Janco’s years of experience will help you get the job done.

Contact us to learn more about our capabilities.

The post Janco Celebrates 60 Years of Thermoforming & Packaging Excellence appeared first on Janco Inc.

When outsourcing medical packaging services, companies will need to determine the kind of materials and packaging they need for their specific application. This can be determined before meeting with a vendor or during discussions with a vendor design team. Whether determining materials or adjusting designs, working with a skilled medical packaging vendor can guide you toward the right packaging solution.

In this post, we’ll cover the types of medical packaging and the materials used, as well as how a packaging design team can help you create a more efficient and user-friendly product.

Medical packaging cleanrooms

What differentiates medical device manufacturing and packaging from other types of packaging is the need for cleanroom facilities. Certain types of medical products have to be assembled and packaged within a cleanroom, which is a controlled environment where pollutants such as airborne microbes, dust, and aerosol particles are filtered out to provide the most sterile environment possible.

Janco has ISO 14644-1 Class 7 and Class 8 certified cleanrooms for medical device assembly and packaging services. They’re monitored and tested frequently to ensure that they meet required operating parameters. Plus, all of our medical processes are regularly assessed and verified by thorough internal, independent, FDA, and customer audits.

Before signing with any vendor, ensure they meet the cleanroom standards you need to safely manufacture and package your products.

What type of medical packaging is right for your needs?

Across each of these sectors, several different types of medical packaging are common depending on your unique needs. These include:

• Trays: Medical packaging trays come in a range of different sizes and can be created from several materials. Because of the many ways that trays can be customized, they’re ideal for a range of applications, from syringes to medical devices.
• Multi-Compartment Trays: This type of medical packaging is usually manufactured from a rigid material. Multi-compartment trays are the preferred type of packaging for surgical implants, sutures (nylon, polypropylene, silk, or polyester), and a range of other more sensitive surgical items.
• Blister Packaging: Usually used to contain individual capsules inside of a box, blister packaging is used to protect medication from contamination before ingestion. Typically a peel-able layer is used as a cover, but depending on the nature of the material, blister packs can also be sealed with a push-through lidding used to access individual capsules.
• Pouches: Medical packaging pouches are ideal for use when an oddly-shaped application needs to be contained.
• Cartons: Most commonly used for products that need to be stored at room temperature, cartons are usually manufactured from fiberboards and come in a medical packaging box. You’ll typically find over-the-counter medicine, such as capsule pills, packaged in individual cartons.
• Individual-Wrap Packages: This is a popular choice for single-use applications, such as packaging for syringes. Individual-wrap packaging is usually made from plastic, but this may vary. In some instances, blister packs are also used for extra support in medical needle packaging.
• Shrink Wrapping: Typically made up of polymer plastic film, shrink wrapping is used for medical packaging when a device or item needs to be covered tightly. With heat applied, shrink wrapping creates a firm seal over whatever it is covering.

Medical packaging materials

Because medical devices and packaging often need to stand up to the stresses of sterilization, finding the right material is essential. Here are some of the types of materials used in medical packaging.

• Plastic-Plastics are a diverse and versatile set of materials used for both film shrink wrapping and medical device trays.
• Foam-Polyethylene closed-cell foams are great for medical applications because they are sturdy, easy to process, and are water resistant, among many other benefits. Foams are typically used in thermoforming medical trays.
• TPU-Thermoplastic polyurethane, or TPU, is a family of plastic films that are water, abrasion, and fungus resistant, as well as flame retardant. Available in a range of opacity, this elastic-type material meets standards for use in medical devices and complies with FDA regulations. Because it is puncture resistant and non-particulating, it is often used in packaging for protecting sharp, cutting items.

How medical packaging design helps your customer

A medical device packaging project is typically viewed as a success if the product is delivered safely and to specifications. We would argue design and ease of use are important as well.

Choosing a vendor with an in-house design team helps you come up with a packaging solution that not only meets all requirements, but is well designed, cost-effective, and easy to open and use during critical medical procedures.

For example, custom procedure trays (CPT) that are designed and built to hold instruments used during surgery are typically designed and set up for your specific procedure needs, with instruments placed in order of their chronological use.

Understanding not only how to get your product to market, but also how they will be used, helps you and your packaging vendor develop the best solution.

Medical packaging regulations and requirements

Packaging for the medical industry is heavily regulated to ensure the safety and sterilization of important products. You will need a vendor that can provide the right clean room capabilities, whether that’s sterile class 1 or ISO 14644-1 Class 8 class cleanroom.

Our team goes to great lengths to ensure we adhere to the standards and regulations that exist for the manufacturing of medical packaging. Our approach to material supplies ensures that you have access to foam or plastic materials suitable for non-sterile, or sterile class I, II, III.

Our medical manufacturing division includes ISO 14644-1 Class 7 and Class 8 certified cleanrooms and Janco is an FDA registered establishment.

Our medical packaging capabilities

Even within the medical field, there are several different sectors of medical packaging with varying needs. Our team has experience creating medical packaging for the following specialties:

• Orthopedics
• Vascular
• Respiratory
• Endoscopy
• Laboratory
• Cardiology
• Ophthalmic
• Spinal and Biologics
• Dental
• Pharmaceutical
• Veterinary
• Drug delivery

In need of medical device packaging?

Janco is proud to offer high-quality and cost-effective thermoforming and compression-molded services for the medical industry. Our team will work with you from concept and design to the assembly and packaging of your product to deliver the results you need.

The post Types of Medical Packaging – Everything You Need To Know appeared first on Janco Inc.

Janco has provided complete packaging services for both industrial and medical applications for 60 years. In this post, we’ll share what our years of experience have taught us about finding the right packaging manufacturer and the questions you should ask your packaging vendor.

Different Industries, Different Packaging Needs

The approach to packaging varies depending on the industry, so it’s key to ensure your packaging vendor has the capabilities you need, whether you’re making athletic equipment or medical devices.

To better understand what different market segments need when searching for packaging solutions, we break down capabilities and the questions you should ask by industry:

Medical Packaging Services

For packaging medical devices, your vendor must offer the right capabilities to meet regulatory requirements. You’ll also likely want to consult on design and materials to manage cost and speed-to-market. Make sure to be clear about your needs, including guidance on FDA regulations, material selection, sourcing, labeling, and prototyping.

As you vet potential wholesale packaging services, here are some questions you should be asking:

• Are you cleanroom certified?
  • At Janco, we manufacture all medical packaging according to regulations specific to the industry. We are FDA registered and hold ISO 13485 certification, as well as Class 7 and Class 8 cleanroom certifications.
• Do you offer manufacturing and packaging capabilities?
  • Conducting medical device assembly and packaging within the same facility can save your company time and money.
• Do you offer labeling services?
  • Make sure you fully understand what a vendor is offering in their “packaging services” and discuss specific capabilities such as labeling, gluing and folding.
• Do you offer internal and external packaging capabilities?
  • Medical devices often need multiple levels of packaging and sealing. Make sure your packaging vendor can provide each step needed.
• Can you also manufacture related packaging materials, such as tray or foam packaging?
  • To increase efficiency, look for packaging services that can provide accessory packaging needs in house.
• Do you offer design services?
  • If you have a packaging or assembly challenge, your vendor should have the skills, capabilities and experience to manage the design process for you.
• What is the cost and turnaround time?
  • Supply chain issues and material sourcing is a major challenge for all industries. Search for vendors that have a proven sourcing strategy and speed-to-market.

Want to know more about what an experienced wholesale medical packaging service can offer? See what Janco offers here.

Industrial Packaging Services

Packaging for industrial applications does not have the same requirements as the medical industry, but may come with other challenges. Having an experienced packaging vendor to come up with creative solutions is especially helpful to start-up companies looking to provide cost-effective, high-value products in a new way.

When selecting complete packaging services for your industrial product, consider asking these questions:

• What industries do you support?
  • Janco provides a wide-range of packaging solutions for the following industries:
    • Automotive
    • Athletics
    • Electronic
    • Heavy equipment
    • Manufacturing
•  What products do you have experience providing packaging for?
  • A company experienced in your industry may not have the skills needed to effectively design packaging for your product. Look for vendors who understand the challenges of your industry and products you make.
• Do you offer design services?
  • New designs and disruptive technology require new ways of thinking about wholesale packaging. Look for vendors that offer skilled design services.
• What is the cost and turnaround time?
  • The price your vendor quotes won’t carry much weight if it doesn’t get to the customer on time. Make sure your packaging service has a proven record delivering on-time.
• Do you have issues with sourcing and supply chain?
  • Again, supply chain is a common challenge, so ensure they have a firm grasp on the market and how best to source materials needed.

Have an industrial packaging application challenge? You can find more information about Janco’s industrial packaging here.

Contact us about our complete packaging services.

With 60 years of experience, Janco offers significant expertise in a wide range of packaging applications. We are happy to offer expertise, whether in design or delivery, to ensure you get the wholesale packaging solution you need.

The post Complete Packaging Services: Finding the Solution That’s Right for You appeared first on Janco Inc.

Medical instrument manufacturers want to meet the needs of the physicians, nurses and other practitioners that use their products, yet they also must be concerned with safety, sterilization and keeping costs low.

A multi-compartment disposable tray for medical use meets the needs of both producer and user. Light-weight plastics ensure lower manufacturing and shipping costs. Disposable trays with compartments also make accessing instruments easier for medical professionals.

As a manufacturer with certified cleanroom capabilities, Janco has significant experience in designing and producing disposable trays for medical devices and instruments. In this post, we’ll examine the benefits multi-compartment disposable trays offer and some of their many uses.

About Multi-Compartment Trays

Multi-compartment disposable trays are used in hospitals and clinics to hold medical instruments and devices during procedures. These trays are sterilizable and customizable, made of a rigid material with separated sections created during thermoforming.

Disposable trays with compartments can hold instruments that are packaged separately, hold individually packaged instruments and devices within the tray’s entire packaging, or serve as the packaging for all components combined.

Benefits of Multi-Compartment Disposable Trays

When it comes to designing the delivery of medical devices, here are some benefits disposable trays with compartments offer.

Preferred for surgical uses – Surgery requires precision and focus, which is why multi-compartment trays are the preferred type of packaging for surgical implants, sutures, and other more sensitive surgical items. These devices and instruments are in separate compartments, packaged in the order in which they are required for the procedure, reducing the risk of mistakes and ensuring items can be accessed quickly.

Customizable – Disposable trays with compartments are highly customizable, offering manufacturers the ability to create a tray to fit the medical devices and instruments they need in a variety of applications.

Sterilizable – When working with a supplier that has cleanroom capabilities, you can design multiple compartments that can be sterilized.

Multi-Compartment Disposable Tray Uses

There are two main types of trays that can be designed with multi-compartments: surgical and sterilization trays.

Surgical Trays
As the name suggests, surgical trays are for holding instruments and devices during surgery. These customized procedure trays, also known as CPT, are designed and set up for specific procedures, from cardiac surgery to dental procedures.

Sterilization Trays
Sterilization is an important step in protecting the health and safety of patients. These customizable trays can be designed for specific instruments to align with your needs.

Our sterilization trays, made from plastic materials, are designed to protect instruments during cleanroom sterilization and storage.

Janco Capabilities

Janco has decades of experience working with the medical industry packaging the important tools, devices and equipment they need each day. We can bring your unique medical packaging design and manufacturing needs to life with our state-of-the-art equipment and material. With Janco, you have an expert partner by your side from start to finish.

Our custom thermoforming processes allow you to tailor the tray to your unique needs throughout the design phase of your project. Our multi-compartment trays can be pre-loaded with sterilized instruments organized by procedure type and can include lids, peel tops, and unique divider systems.

The materials we use are all approved for several different modes of sterilization and trays are manufactured in class 8 Cleanrooms and packaged and sealed in class 7 Cleanrooms.

With Janco, you not only get a packaging vendor to fulfill your orders but a partner who can help you at every stage of the packaging process.

Searching for a partner for your medical device project?

Learn more about our capabilities in medical device assembly and packaging. Talk to us today.

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Different foams have wide variations in density, durability, firmness and overall performance. In the medical industry, you need materials that are medical grade, biocompatible and FDA compliant.

When it comes to medical packaging, closed-cell polyethylene foam is a great option.

At Janco Inc, we’re experienced in using closed cell polyethylene foam and can help you choose the right material and application for your medical packaging. Here’s what you need to know about closed cell polyethylene foam for your next project:

What is closed cell polyethylene foam?

Closed cell polyethylene foam is a durable and lightweight closed-cell material made of millions of tiny bubbles, sealed off from each other. It is a popular choice for medical packaging because it is resistant to moisture and chemicals, and has excellent insulation properties.

Benefits of closed cell polyethylene foam

Closed-cell polyethylene foam is a popular choice for many applications, including medical packaging, because of its many advantages over other materials. Here are some of the benefits:

• Easy to process – Closed cell polyethylene foam is easy to manipulate and fabricate, making it a great choice in manufacturing and packaging. This type of foam is easily die cut and works well with compression molding and thermoforming.
• Cost-effective – Its high load bearing characteristics mean that smaller amounts are needed to protect products, saving manufacturer costs on materials.
• Water impermeability – The closed-cell nature of the material means water does not pass through the foam, making it an effective solution for preventing moisture problems.
• Insulating – This highly-dense material insulates extremely well against heat, noise and vibrations.
• Durable – The material is light yet strong which makes it tear-resistant and long-lasting.
• Non-particulating – This material doesn’t shed small particles that could become contaminants in a clean space, making it a great choice for the medical industry.
• Sterilizable – Unlike many other materials, closed-cell polyethylene foam can undergo the strains of sterilization and still hold up strong.

Types of closed-cell polyethylene foam

This versatile material comes in a variety of forms for a wide range of applications. These types include:

• Polyethylene sheets – Foam sheets that come in various thicknesses and can be used for a wide range of applications, from packaging to insulation of buildings.
• Polyethylene rolls – Foam rolls are used for piping and plumbing purposes, medical supplies and other health care products. You can find it in a variety of shapes and thicknesses, making it a versatile choice. While this is an effective foam in some cases, when it is in a thinner state it is less durable than foams of greater thickness.
• Volara – This flexible foam has a wide range of uses. Beyond its popularity in the medical industry, Volara is ideal because it’s both FDA-compliant and non-toxic, containing no chlorofluorocarbon, hydrochlorofluorocarbon, or hydrocarbon-blowing agents.
• Closed cell cross-linked polyethylene foam – This type of form is air, stain and water resistant, which also makes it mold and mildew resistant. It is used extensively in the packaging of medical products and equipment.
• Zotefoam – The world’s largest manufacturer of lightweight crosslinked polyolefin block foams, which offer effective cushioning and resistance to water and some chemicals.

Closed-cell polyethylene foam and Janco

We frequently work with closed-cell polyethylene foam when creating medical packaging because it’s one of the most effective materials for meeting our customers’ needs.

Here at Janco, we specialize in Volara foam distribution. Volara foam is used in projects across several medical manufacturing capabilities, including compression molding, thermoforming, and die cutting. We also use Zotefoam, another effective foam product for its easy manipulation and resilience.

Regardless of the material used, our medical device and packaging staff is skilled in ensuring products meet all standards, supported by an inspection team that performs thorough validation testing in accordance with ASTM, ISO, or custom standards.

Closed-Cell Polyethylene Foam for Your Medical Packaging Needs

When you need custom packaging services for the medical industry, Janco Inc has the experience, design skills and state-of-the-art equipment you can rely on to get the job done right.

Contact today to discuss our medical packaging capabilities.

The post Closed-Cell Polyethylene Foam for Medical Packaging appeared first on Janco Inc.

Thermoforming is one of the most well-known manufacturing capabilities for a good reason – it’s ideal for a wide range of projects spanning several unique industries and needs.

Our team works with clients from design and material selection through to production and labeling to guarantee your project is cost-effective, precise, and high-quality.

Below, we’re answering the most frequent questions our team gets asked about thermoforming.

What is thermoforming?

Thermoforming is a manufacturing capability used for a wide range of essential projects across several different industries. Our team offers both thin gauge and thick gauge thermoforming, putting our decades of experience to use while bringing your custom products to life.

The process begins by heating a thermoplastic sheet until it is malleable, stretching that sheet into or over a single-sided custom mold, and then holding that position as it cools and solidifies into the desired shape.

Then, the sheet is clamped into a custom holding device and heated by an oven using either convection or radiant heat until softened.

Finally, the sheet is held over a mold and pressed into or stretched over the mold using vacuum pressure, air pressure, or mechanical force. The sheet, once softened, conforms to the shape of the mold and is held in place until it cools, and any excess material is removed.

What industries use thermoforming capabilities?

We provide custom thermoforming for several unique industries, including:

• Medical
• Athletics
• Automotive
• Electronic
• Heavy equipment
• Manufacturing
• And more

What can you make with thermoforming?

Every project we take on is custom, so regardless of your needs, we’ll assess the project and determine how we can help.

Most commonly, our team uses our custom thermoforming capabilities to create:

• Blister packaging
• Covers
• Clamshells
• Automation trays
• Enclosures
• Inserts
• Protective cases
• Industrial process tray
• Automotive component packaging
• Electronics packaging

What are the benefits of thermoforming?

One of the key questions we get asked is why thermoforming is so commonly used across multiple industries. Two of the primary benefits are short lead times (meaning you get your product quicker, without sacrificing quality) and low tooling costs (which means you’ll spend less while still getting a high-quality product).

Quicker production time includes fast prototype development, allowing for any necessary tweaks to be made before your product goes into production.

Other major benefits include:

• The ability for you to provide extensive design input
• A large quantity of colored and paintable plastics to customize your product
• Several unique finish options, including multiple patterns and textures

How do I know what material to use?

Our team of experts is here to assist you with every part of the process, including offering guidance for material selection. Many projects have unique requirements, so we’ll help you understand the best material for desired properties such as:

• Biocompatibility
• Anti-static
• Fire-retardancy
• Impact
• Abrasion resistance
• And more

What materials are used for custom thermoforming?

When you work with Janco, you benefit from our long-standing foam and plastic partnerships that offer a distinct advantage when it comes to sourcing, supplying, and meeting your high-volume, mid-volume, or low-volume needs, with competitive pricing at every level.

We work with a wide range of materials, including:

• PET, PETG, PETE (polyethylene terephthalate)
• HIPS (high impact polystyrene)
• Acrylic
• PVC (polyvinyl chloride)
• Kydex®, a trademarked acrylic/PVC alloy
• ABS (acrylonitrile butadiene styrene)
• PC (polycarbonate)
• PP (polypropylene)
• PS (polystyrene)
• HDPE (high-density polyethylene)
• TPU (thermoplastic polyurethanes)
• TPO Foams (thermoplastic olefins)
• And others, depending on your application

What are your thermoforming capabilities?

Janco’s Core Thermoforming Capabilities

• Bed size: 29″x 32″ gauge range of .007″ to .060″
• Thermoforming and Fabrication Cleanrooms certified to ISO 14644-1 Class 8
• Fully-automated inline thermoforming machines

Heavy Gauge Pressure-Thermoforming

• Bed size 48″ x 72″, Gauge range of .006″ to .500″ with 24″ depth of draw
• In-house design assistance, prototype, REN, and production tooling
• ISO 13485 Certification, FDA Registered
• Thermoforming and Fabrication Cleanrooms certified to ISO 14644-1 Class 8

Custom Thermoforming with Janco

Turn to a team you can trust for the solutions you need.

Our team prides itself on offering value-add services that ensure your products offer the highest return on investment. We work hard to bring your visions to life with custom designs, innovative technology, and high-quality materials – all at an unbeatable cost.

For about six decades, we’ve worked on custom jobs for clients who know that they can trust us for all of their thermoforming needs.

Have a project in mind or want to learn more about our custom thermoforming process? Get in touch with us!

The post Frequently Asked Questions: Custom Thermoforming appeared first on Janco Inc.

One of the biggest sources of pride for our team is putting our decades of experience and innovation to use helping clients find tangible solutions to issues that arise as they create, design, and package new products.

The Acetabular Reamer

The Project

A start-up company specializing in single-use instrumentation for orthopedic joint reconstruction approached us with a prototype that they needed help packaging. The instrument was a reamer designed to remove necrotic bone from the acetabulum, a deep, cup-shaped structure that includes all three bones of the pelvis and encloses the head of the femur at the hip joint.

The Challenge

The issue with packaging a product like this is that it’s incredibly sharp and needs a durable package to ensure that the instrument remains sterile, with no particulates. Shaped like a hemispherical cheese grater, the instrument presented a unique shape with several sharp surfaces that could create lesions in certain types of packaging.

Our job was to create packaging that would ensure the instrument would remain sterile until its use in an operating room. We worked closely with the clients’ team, taking their design ideas into consideration, and then had our team of engineers put their heads together to create custom packaging that would be reliable and effective.

Our Solution

Blending innovation with manufacturability, we worked off of the original input from the clients while using our own experience to forge a solution that would add value to their product. We decided to thermoform TPU material – the ideal material to ensure that the various sharp edges didn’t particulate and breach the package.

This wasn’t just a one-and-done solution, however. Creating something new involves iterations and our team produced several prototypes with different types of latches designed to ensure that any nurses and doctors handling the instruments would be protected when using them. In all, we created around 10 different sizes varying by around 1mm increments each time.

Eventually, we also settled on using a Tyvek® pouch around the custom thermoformed TPU packaging for additional protection.

The Result

Our clients ended up with custom packaging for a limited launch of their product that was durable, kept the product sterile, and allowed for easy handling by the doctors and nurses while in the operating room.

Through collaboration, innovation, and hard work, we helped produce unique packaging for a product that allowed our clients to distribute an instrument that would go on to be incredibly useful for important medical procedures.

Need innovative packaging for your next manufacturing project?

Reach out to Janco to learn how we can put our decades of experience to use to bring your next manufacturing project to life – no matter how challenging it seems.

The post Case Study: The Acetabular Reamer Project appeared first on Janco Inc.

A doctor’s duty, above all else, is to ensure the safety of their patient. Part of that means knowing that the instruments and tools they use throughout treatment are safe and sterile, which comes down to how those instruments are manufactured, packaged, and handled.

At Janco, our team has served the medical industry for six decades. Our quality assurance processes, understanding of unique industry standards, and cleanroom capabilities are second to none. Below, we answer the most common questions surrounding manufacturing for medical packaging in our own facility and beyond.

Is sterile packaging used for medical devices?

Yes, sterile packaging is used for several types of medical devices, including surgical instruments, catheters, single-use instrument trays, and more.

Why do we sterilize packaging materials?

Sterile packaging is an essential component of contract medical manufacturing. When surgeons and doctors utilize certain instruments on patients, it’s crucial that those instruments are kept free of particulates and other contaminants that may harm the patient. Surgical trays, for example, which can contain a wide range of instruments and tools, have to be kept sterile before entering the operating room, as any contamination can lead to infections and other complications with the patient.

Patient safety is the main priority of every doctor, so ensuring the sterility of medical instruments and devices used for treatment or surgery is key to the effectiveness of the duty. Sterile instruments prevent the spread of disease and bacterial infections.

How are packaging materials sterilized?

There are a number of potential methods to sterilize packaging materials. Our team manufactures packaging and products in sterile environments, our ISO-certified class 7 and 8 cleanrooms, and then sends them to an outside partner to be sterilized.

Cleanrooms ensure that products and packaging aren’t compromised by particulates and other contaminants that could compromise the devices or instruments.

What are the types of sterilization?

Methods of sterilization include ETO, gamma, e-beam, steam autoclave, and dry heat. The chosen method depends on the material used to package a product, ranging from plastic or paper to Polyfilm plastic tubing.

What is the shelf life of a sterile package?

According to the CDC, practices for sterilized instruments can be based on either date of sterilization or specific events, such as the packaging being opened. Some facilities put dates on every sterilized package based on shelf-life practices, but it’s more common that manufacturers utilize event-related shelf-life recommendations. This dictates that instruments or devices should remain sterile until a specific event causes contamination. That could include the pouch or seal being intentionally opened, accidentally torn or scratched, or wet.

Regardless of the date or event, all packages that require the internal instruments or devices to remain sterile should always be thoroughly inspected before use to verify that the package is not wet, torn, or damaged in any way. In some cases, the contents of the package may need to be resterilized before they can be used by doctors or surgeons.

Can you write on sterile packaging?

If writing is done on a sterilized package, it should be done on the plastic side, if there is one, and should be done using a non-toxic marker. This is because the plastic portion of the packaging is not permeable to the sterilant and will keep the content protected.

Labels for sterilized packages should typically include the date of sterilization, the expiration date (if there is one), and the type of sterilization used.

What is Tyvek® packaging?

Tyvek® is high-density polyethylene used to create pouches for sterile packaging needs. Its makeup, which consists of continuous filaments, creates a barrier that blocks particulates, microbes, and other contaminants from entering the pouch. Most commonly, Tyvek® pouches are often used for implants and other medical devices.

Our team purchases pouches from our circle of trusted vendors, performing the sealing in our facilities using a pouch sealer in our class 7 cleanroom.

Medical Manufacturing with Janco

Our team has experience working across several sectors of the medical industry on contract manufacturing projects, including:
​

• Orthopedics
• Vascular
• Respiratory
• Endoscopy
• Laboratory
• Cardiology
• Ophthalmic
• Spinal and Biologics
• Dental
• Pharmaceutical
• Veterinary

Several of these fields require sterilized packaging to insure devices, instruments, and other tools are kept safe from contamination by particulates and other matter.

Ready to get started on your next project?

If you have questions about our process, want to know more about our team, or have a medical manufacturing project requiring sterile packaging that you think Janco can help add value to, reach out to us.

The post Frequently Asked Questions: Sterile Medical Packaging appeared first on Janco Inc.