Secondary Packaging

Folding Cartons

Folding cartons provide excellent secondary protection for individually packaged sterile products as well as multiple unit packs. For multiple unit packs, the carton can be designed as a dispenser carton by including a perforated area into the carton. The user exposes the product for easy removal by their customer using the perforated section.

There are a great many styles of folding cartons available and numerous specialized features that can be added to these design styles. Although some simple styles can be ordered as off-the-shelf items, the vast majority of folding cartons used for medical products are custom designed to fit the product and to incorporate the specialized features which enhance the product presentation.

The best way to determine the style and features that will best protect and enhance your product is to work with an experienced packaging engineer or carton designer. A poor fit between the carton and the inner package/product will often result in damage, the cost of which usually exceeds any cost savings gained by using less than ideal off-the-shelf cartons.

Corrugated Shipping Containers

The shipping container is a corrugated box, which has sufficient strength to be used for shipping, sterilization, and storage of medical devices or any other medical product. Corrugated fiberboard is made up of two separate components, the linerboard and the medium. The linerboard is the flat facing and the medium is the fluted paper glued between the liners.

There are many flute profiles used in the construction of corrugated board. The arched flutes create a very rigid and strong medium. The flutes also act as a cushion against minor impact. The most common configurations include B-Flute, C-Flute, E-Flute and Double Wall constructions. The type of corrugation used in the construction of a shipping container is determined by the physical size, weight, and fragility of the product(s) going inside the box.

The type of flute is only part of the equation in determining the strength and durability of the container. Since different grades of material can be used for both the linerboard and the medium, burst strength ratings are also important. Simply put, burst strength is a standardized test method used by all corrugated manufacturers to rate the penetration resistance of the container wall. The higher the rating, the stronger the box. 200-pound test is a commonly used material but may not be adequate for delicate products or heavy products.

The most widely used style of shipping container is the RSC (Regular Slotted Container). The RSC can be used in conjunction with inner-packing materials including corrugated inserts, bubble wrap and rigid or soft foam inserts to further protect the product.

Shipping containers and folding cartons, are defined first by style, second by the inside dimensions Length x Width x Depth, third by the material (flute style and pound test for corrugated) and finally if the carton is printed or plain.

Dimensioning a box:

Dimensions are described based on the opening of an assembled box. The opening can be located on the top or the side, depending on how the product will load into the box.

Length - The larger of the two dimensions of the opening.

Width - The smaller of the two dimensions of the opening.

Depth - The side perpendicular to the length and width.