OP Products - Safely and efficiently package small batch sizes

OP sets are now assembled according to indications and combined into multipacks. The requirements for the packaging process are high. Multivac offers several solutions that enable flexible and efficient picking of OP products and also support, if needed, in packaging development, material selection, and sampling.

Swabs, compresses, scalpels, scissors, tweezers, dressing materials, surgical suture materials, operating room sheets, and clothing: modern OP sets today consist of a variety of ready-to-use single-use or reusable components that are assembled, packaged, and sterilized according to indications. Subsequently, the sets are often combined into multipacks and enclosed with secondary packaging that protects them from mechanical impacts.

The variety of packaging variants makes the process particularly demanding. Often, as many packaging variants as possible are to be produced with a single packaging machine, or there are special requirements that require very specific machines. Worldwide, only a few providers of packaging solutions are broad enough to cover all requirements. One of them is Multivac.

The company specialized in packaging is among the world's leading providers of packaging solutions for medical sterilization goods. In Germany, Multivac is one of the first manufacturers of packaging machines that developed and introduced a industry-specific solution as early as the 1960s. Over the past 45 years, continuous investments have been made in this business field, and the portfolio has been expanded segment by segment.

Multivac Clean DesignTM Machine Concept

The packaging machines of the new generation from Multivac are based on the machine concept Multivac Clean DesignTM. This concept fully meets the requirements of the medical device and pharmaceutical industries for transparency and process safety, cleanroom suitability, and flexibility. This means that medical and pharmaceutical products are packaged safely, reproducibly, and economically.

The packaging machines designed according to Multivac Clean DesignTM can be thoroughly cleaned according to industry standards. The smooth surfaces, rounded edges, and the materials used contribute to this. All niches or dead angles where products could get caught unnoticed have been consistently minimized.

Efficient for Small Batch Sizes

The R 145 offers the company a highly capable entry-level model in the field of thermoforming packaging machines. It allows OP materials and other medical technology products to be reliably and efficiently picked and packaged in small to medium batches. Thanks to its modular design and the freely selectable tools, the R 145 can be easily expanded and adapts flexibly to changing requirements.

The semi-automatic tray sealer T 260 is also designed for packaging OP materials in small to medium batches. Changing the sealing tools is very simple with this tray sealer. This is facilitated, among other things, by a tool recognition system that ensures the respective tool is matched and checked for the packaging formats to be produced.

Both models enable seamless traceability and reproducibility of individual production batches. Measurement and control technology, as well as all other equipment, are focused on process and product safety and on producing very high-quality seals.

With the C 400 TC, Multivac also offers a special chamber machine with temperature-controlled sealing bar, built according to the Multivac Clean DesignTM. Compared to standard impulse sealing, this sealing technology offers advantages in process safety and reproducibility.

Packaging of Sensitive Products

In 2012, the company introduced an integrated packaging system for packaging sensitive products or combination packs. This solution also achieves unique efficiency when packaging small batch sizes. "With the new machine concept, we have largely separated process and technical rooms," explains Verena Weiß, Product Manager MCP (Medical, Cosmetics & Pharmaceuticals) at Multivac. "All installation units such as hoses, cables, and valves have been moved from the inside of the machine to the back. In addition to ensuring security against loss, the machine concept also guarantees seamless documentation and traceability of the packaging processes."

"With the integrated packaging system, we achieve maximum process safety, as it guarantees, among other things, complete line clearance and meets the highest requirements for flexibility," Weiß adds.

The packaging machine is clad with a transparent front made of polycarbonate. The large doors can be easily opened. This design feature further improves visibility and accessibility of the machine in terms of safe line clearance.

Frequent format changes can be carried out quickly and, above all, reproducibly. For changing the thermoforming and sealing tools, Multivac offers a drawer system that allows quick exchange of upper and lower tool parts—even for complex punch tools.

Simple Operation, High Process Safety

All mentioned models are equipped with an intuitive user interface that allows easy setting of production parameters on the clear control panel, even for untrained personnel.

The complete measurement and control technology of Multivac machines is designed for process safety. Critical parameters such as time, pressure, temperature, and vacuum are continuously adjustable and monitored during the entire process, with visual feedback for the operator.

The machine control can be extended with identification systems such as code and RFID scanners. These are used both for user recognition and for identifying the correct materials and tools. Additionally, the control system features an integrated audit trail function, allowing the entire process history to be stored. The ability to transmit process data to management execution systems ensures complete product and material traceability.

The high throughput and minimal changeover times make Multivac's packaging machines particularly economical. The company also supports customers with validation and calibration of their machines, assistance in finding optimal packaging materials for sterilization processes, and packaging development.

At its newly established Training & Innovation Center in Wolfertschwenden, the company offers customers a complete infrastructure, including consulting for packaging development. From the initial idea through concept and material selection to technical implementation on in-house packaging machines—Multivac provides space, expertise, and technological support for all phases of a development project. Companies utilizing this offer have access to the full range of technologies of the packaging specialist, including automation solutions.

Furthermore, the company offers a broad spectrum of operator training. The trainers combine modern training techniques such as e-learning, virtual classrooms, and in-person training to ensure continuous knowledge building over an extended period.