Compact Innovation: Shawpak Delivers Space-Saving Dual-Pack Medical Device Solution

Shawpak were approached by an overseas medical device manufacturer facing a significant challenge, clean room space. Shawpak were able to help by developing a complete primary and secondary packaging system within a tightly restricted cleanroom footprint. The brief demanded high throughput, stringent quality control and zero compromise on regulatory compliance, all while maintaining seamless integration.

Shawpak had an ideal solution, its Linear Blister Form-Fill-Seal (FFS) system, tailored to produce a male-formed rigid blister directly from roll stock. This formed blister served as the primary pack for a delicate medical device. After device loading, the Keyence vision system was employed to ensure correct positioning and the presence of critical device features.

The blister was then sealed with a Tyvek® lid, inline printed with a high-definition printer, and inspected again using advanced Keyence vision technology to detect any print or material defects. This precision-first approach ensured that no compromised pack could proceed to the next stage.

The sealed primary pack was automatically transferred to a die-cutting station to shape the outer pack profile. A Universal Cobot — a collaborative robotic arm — was then deployed to remove the completed pack, separate trim waste, and deposit the finished unit into the next phase of the process. The Cobot’s agility was instrumental in navigating the confined workspace, performing dual tasks of waste management and product handling with ease and efficiency.

The Cobot then loaded the primary pack into a Shawpak Rotary Thermoforming 62-25 machine, also equipped with HD printing and Keyence vision for secondary print inspection. Here, a secondary flexible blister was thermoformed around the primary rigid pack, completing a dual-pack configuration that ensured both protection and compliance.

By placing the compact RT62-25 machine at a 90-degree angle to the linear FFS system, Shawpak achieved a tightly integrated system with an exceptionally small footprint — a key requirement for the customer’s limited cleanroom space.

To ensure maximum reliability and integration performance, the Shawpak were built using Rockwell Allen-Bradley control systems, providing a robust, industry-trusted automation platform. This control infrastructure not only enhanced machine performance and diagnostics but also ensured seamless communication between system components for precise, synchronized operation.

The project highlights Shawpak’s capability to integrate automation, robotics, and vision into a cohesive system that meets strict manufacturing requirements. It demonstrates how innovative packaging solutions can also be space-efficient—an essential combination in cleanroom environments where precision and adaptability are critical.

Exhibitor Data Sheet