SPECIAL REPORT
Plasma Processing Touted as Green Alternative to Bonding or Overmoulding Metal Parts
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Surface preparation of metal components may require the use of caustic chemicals or other conversion coatings to ensure proper bonding. Plasma-enhanced chemical vapour deposition (PECVD) coating technology provides a more environmentally friendly way to achieve a similar or better result, according to PlasmaTech Inc. (Erlanger, KY, USA; www.plasmatechnology.com).
By depositing a thin polymerized coating, it is possible to create a tie or interface layer that permits direct bonding or overmoulding to the metal surface. The resulting bond performance often surpasses what can be achieved with conventional methods, according to the firm. Plasma polymerized thin films can be deposited directly onto a plasma precleaned substrate without exposure to the atmosphere. The continuous multistep process provides adhesion to the base substrate, as the polymerization occurs at the atomic level.
UV-Curing Adhesive Clears Air at Medical Disposables Production Plant
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A manufacturer of PVC-based anaesthesia masks, respiratory equipment, and tubing products recently sought to update its production processes. One area that it targeted for improvement was the solvent adhesive technology it was using, which required intensive manual labour and caused health and safety issues. An air extraction system was needed to ensure the air was clean and free from harmful chemicals given off by the solvent-based adhesive. To bond a rigid PVC mask shell to a flexible PVC inflated mask cushion, Eurobond Adhesives Ltd. (Sittingbourne, Kent, UK; www.eurobond-adhesives.co.uk) recommended to the firm that it replace the solvent with a USP Class VI UV-curing adhesive.
Vitralit 7989 is a medium-viscosity product that can be used for bonding products such as chest drain bags, blood pressure transducers, stopcocks, surgical masks, and arteriograph manifolds. By switching to this product, the aforementioned device manufacturer was able to semiautomate production and dismantle the air extraction system, thus reducing energy consumption. Preproduction trials carried out using Vitralit showed a 60% increase in throughput, a reduction in the amount of adhesive used to fulfill orders, and an overall healthier and safer environment for personnel.
Device Manufacturer Embraces Responsible Care Initiative
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In addition to complying with ISO 14001 at all of its facilities, a manufacturer of medical devices, drug delivery systems, and personal care products has agreed to obey the tenets of the Responsible Care initiative at its main plant in Kontiolahti, Finland. Under the agreement, Medifiq (Vantaa, Finland; www.medifiq.com), formerly Perlos Healthcare, will pursue continuous improvement in all aspects of health, safety, and environmental performance and maintain open channels of communication about its activities.
A global voluntary initiative of the chemical industry, the goals of Responsible Care fall neatly in line with Medifiq’s values of quality, commitment, and competence, says the company’s quality manager, Janne Alava. The company promotes environmental, health, and safety principles internally through staff training and within society at large by communicating these values to the public, he adds. A focus on continuous improvement has led to an increase in the use of recycled materials, improvements in health and safety among the staff, and a year-on-year reduction in total waste output.
Materials Supplier Introduces Sustainable Polypropylene
Bio-based materials replace 50% or more of the petroleum content in a new family of resins, yet they have nearly the same physical characteristics and price point as traditional polyolefins. Introduced by Cereplast Inc. (Hawthorne, CA, USA; www.cereplast.com), Hybrid resins, also known as Biopolyolefins, can replace conventional petroleum-based plastics in a number of sectors, including the medical device market, according to the firm.
“The Hybrid resin can be used in a variety of medical applications,” says Kevin Oates, who handles public relations for the firm. “One example is medical trays, which hold an assortment of medical instruments, because the resin is capable of withstanding most sterilization processes. Another [application] might be the housings of monitoring and diagnostic devices.”
The material can be used in a variety of manufacturing processes, including injection moulding, thermoforming, profile extrusion, and extrusion blow moulding. It meets toxicity requirements as set forth by ASTM D6400-04.
Bag-in-Box System Reduces Packaging
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A bag-in-box packaging system for pharmaceutical products combines a cost-effective design for packing, storing, and distributing liquids, powders, and particulate products with environmental benefits.
Developed by Johnsen & Jorgensen (Dartford, Kent, UK; www.jjpack.com), the SmartPack comprises a plastic double-layer bag and corrugated outer box. It can be stored flat when not in use.
The stand-alone inner bag squares up when filled; it does not rely on external packaging to maintain its shape. The external corrugated box makes it easy to palletize the products and provides a large scope for printing.
The corrugated outer box, which is biodegradable, represents about half of the material used; the entire packaging system uses only a fraction of the plastics used by standard bulk containers. Because it can be shipped and stored flat when not in use, the packaging can help companies to dramatically reduce their carbon footprints. The SmartPack comes in five sizes and six closure types. An open-ended version is available.
Bureau Helps Med-Tech Manufacturers Explore Green Design
Regulatory and safety factors notwithstanding, medical companies need to be aware that environmental issues increasingly will have an impact on their bottom line, according to Insight Product Development (Chicago, IL, USA; www.insightpd.com), a design bureau that has worked with such firms as Johnson & Johnson and BD. Medical products that align with a green lifestyle will help the environment, but also create an emotive connection on the part of the user to the brand.
Safety concerns will hinder traditional approaches to sustainability such as reuse and recycling, but med-tech companies can implement green design principles in other ways, according to the firm. Selecting materials based on their environmental credentials, reducing energy use in assembly and distribution processes, exploring sustainable packaging solutions, and adopting design-for-disassembly principles are just some of the ways in which device manufacturers can develop more-sustainable products, says the firm.
By evaluating the stages of a product’s life cycle while taking into account the product’s characteristics and regulatory constraints, the design bureau maintains that it can help med-tech manufacturers develop appropriate sustainable practices.
