Custom Thermoformed Pocket Tape Solution for the Medical Products Industry

The Challenge:

A high-volume medical-test manufacturer needed an automated packaging system that would easily integrate into their existing system and meet stringent packaging and quality requirements.

The product, a small medical test kit designed for direct consumer use, required one component to be packaged separately in plastic. It needed to be protected through packaging, storage and shipping and distributed as individual containers, with 100% accuracy and consistency.

Because the product sells in the largest drug stores across the U.S., the packaging also had to be aesthetically pleasing and easy to use.

The Solution:

Keaco designed a custom thermoformed pocket tape solution whose material and design gave the strength and rigidity to physically protect the device, while meeting cleanliness and ESD requirements.

We helped implement a die-cutter into the customer’s process, so that after packaging in a continuous format and sealing with cover tape, they could die-cut the compartments individually into a consumer-ready shape.

A matte finish reduced glare for vision systems, and 100% pocket inspection with logged measurements and lot traceability held quality at volume.

The Results:

Over 4.6 million units produced annually for the project.

Packaging that met both technical specs and consumer aesthetic requirements, now found in virtually all U.S. drug stores.

Packaged in the U.S. and distributed worldwide.