Guest Blog: Business Goals Drive Shifts in Materials

The medical device industry constantly evaluates product and packaging materials and designs to meet business objectives, sustainability targets, and changing consumer preferences. Tactics to achieve these goals often necessitate changes in materials and the adoption of reusable concepts.

However, any material transition must also deliver a positive patient and caregiver experience without negatively affecting costs, product quality and safety, operational productivity, supply chain efficiency, or regulatory compliance. Ideally, any material transition also helps the company achieve its sustainability goals. So, the materials of greatest interest move the medical device industry toward a circular economy and smaller carbon footprint. This favors transitions to recyclable materials, containing recycled content, and/or derived from renewable, bio-based sources.

Jorge Izquierdo, VP Market Development, PMMI

One tool to help select and adopt new materials is the PMMI/Flexible Packaging Association collaboration Transitioning Flexible Materials Best Practice report. Available from PMMI Media Group Custom Research, the proprietary research arm of PMMI, The Association for Packaging and Processing Technologies, and prepared in conjunction with the Flexible Packaging Association and PMMI’s OpX Leadership Network, it serves as a guide for medical device manufacturers and their OEMs. It notes that the transitioning process requires careful planning, testing, and evaluation to determine whether a new material is compatible with existing machines or requires new equipment.

Also in the report, a flow chart defines the tasks associated with transitioning flexible films, and a RACI matrix shows the responsibilities of the stakeholders that should be involved in the process, including packaging design and development, operations and engineering, marketing/brand owner, OEM, and material supplier/converter personnel. Step-by-step guidance leads the transition through feasibility, design and development, pilot testing, tracks for legacy or new equipment, commissioning, qualification and verification, supply chain scale-up/commercialization, and evaluation.

Another resource, the PMMI Material Transitioning Dashboard , provides insight into what materials are being used in 44 industry categories, the top 10 materials being phased out, and what replacements will be most in demand during the next three to five years. The fully customizable tool evolved from a PMMI report prepared in collaboration with Ameripen, 2023 PACKAGING COMPASS: Evaluating Trends in U.S. Packaging Design Over the Next Decade and Implications for the Future of a Circular Packaging System , and enables users to tailor the data to their industry and business to maximize the usefulness of the information.

For example, the Dashboard reveals that the materials most likely to be phased out in the Life Sciences/Pharma/Healthcare sector are molded pulp, polystyrene (PS), polyvinyl chloride, polyurethane and PS foams, and multi-material structures. Preferred replacements in this category include post-consumer recycled rigid and flexible packaging and materials with recycled, compostable, or bio-based content.

Material selection can also be simplified by using guidelines from the Association of Plastic Recyclers (APR). Following the APR Design® Guide for Plastics Recyclability helps end users and converters design for recyclability. Other important design considerations include consumer accessibility to a collection system for recycling the proposed material, an accessible market for the recycled resin, and adherence to the U.S. Federal Trade Commission’s Green Guides to ensure appropriate label claims.

Another helpful tool, the How2Recycle label, provides consumers with on-pack instructions about proper disposal. Other proactive tactics include third-party testing and certification to verify performance and sustainability claims, enhance credibility, and counter any accusations of greenwashing.

Whatever material choice is made, medical device manufacturers and OEMs must consider equipment needs. Can existing machines handle the new material, or does the equipment need to be replaced or upgraded?

For medical device manufacturers exploring material options, the inaugural PACK EXPO Southeast 2025 (March 10–12; Georgia World Congress Center, Atlanta) offers an opportunity to explore new packaging and processing solutions, observe machinery in action, form strategic partnerships, and take advantage of an array of educational and networking opportunities.

The show, produced by PMMI, will feature hundreds of solutions from 500+ exhibitors spread over 110,000 net square feet. Educational sessions include Industry Speaks , where top experts from the PACK EXPO Partner Program share valuable insights on the latest industry trends and pressing topics, and the Innovation Stage , which includes a dedicated sustainability track.

Networking opportunities (show badge required) include the Opening Reception, sponsored by Domino North America and Multi-Conveyor LLC, on Monday, March 10, from 4:00–5:30 p.m.; the Young Professionals Networking Reception on Monday, March 10, from 7:00–10:00 p.m. at Wild Leap Atlanta (RSVP required ); the Association Partner Pavilion Reception, on Tuesday, March 11, from 3:00–4:30 p.m.; and the Packaging & Processing Women’s Leadership Network Reception, sponsored by Morrison Container Handling Solutions on Tuesday, March 11, from 4:00–6:00 p.m. (RSVP required ).

Discover the latest materials and equipment options at the new PACK EXPO Southeast , the most comprehensive show in the region offering crossover technologies for today’s biggest packaging and processing challenges. For more information, visit packexposoutheast.com.

This article was written by Jorge Izquierdo, VP Market Development at PMMI .