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Aspen Laboratories Reduces Packaging Material Storage by 90 Percent with Korrvu® Suspension Packaging
500 Damage-Free Medical Devices Shipped Per Month
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When Aspen Laboratories, a subsidiary of CONMED, a $100-million medical equipment firm based in Utica, N.Y., merged with Birtcher Medical Systems in March of 1995, the company received patented technology and a line of advanced medical devices that included the world's most commonly used office electrosurgical generator. The technology and products were welcome additions to the Denver-based company's line of medical devices, but, as the people at Aspen quickly realized, the packaging system was a source of wasted warehouse space.
The search soon began for a packaging method that was simple, cost-effective, and reduced the volume of packaging materials. After several months of research, the company selected Korrvu® suspension packaging from Sealed Air Corporation. This proved to be a wise choice that led to a 90 percent reduction in packaging material storage compared to the former package design while providing the same level of protection.
Founded in 1975, Aspen Labs produced the first hand-held, disposable, electronic scalpel, used for cutting and cauterizing. In 1976, the company introduced their first solid-state generator to the Association of Operating Room Nurses. The newly acquired Birtcher Medical Systems manufactured similar medical equipment such as the Hyfrecator Plus® electrosurgical unit, the standard electrocoagulation device in the medical industry for more that fifty years. Used in such diverse specialties as dermatology, gynecology, ophthalmology, plastic surgery, and dental and oral surgery, the six-pound Hyfrecator Plus® requires a packaging design dependable enough to protect its delicate components.
The electrosurgical device was originally packaged in a corrugated container with foam inserts. The unit and accessories were placed into separate compartments and covered by foam that was glued to the inside lid of the corrugated container.
"Using glue with our packaging materials made recycling impossible since it could not be removed for repulping," said Ronald Cosens, vice president of operations at Aspen Labs. "Recycling is becoming more and more a responsibility of the manufacturer. We needed to reflect that."
Empty cartons and bulky foam inserts had to be shipped weekly from a supplier because they took up such a large amount of storage space. Precious warehouse bays, which could have been used for the new Hyfrecator Plus® product line, were occupied by packaging materials.
When Tom Windisch, the local Sealed Air Corporation representative, was called in to provide a solution, he demonstrated the benefits of Korrvu® suspension packaging. Korrvu® packaging's unique design suspends a product in the center of its shipping container to guard against shock and vibration, providing consistent protection even with repeated drops.
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| 1. At the packaging station, the Korrvu® suspension frames are assembled just-in-time. A frame is placed in the center of the shipping container, and the Hyfrecator Plus® unit is then inserted into the center of the box. |
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2. A second Korrvu® frame is placed over the product, fully suspending it between two strong, flexible low-slip films. |
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3. The box is closed, creating tension to hold the product securely within the suspension windows to guard against shock, vibration and damage. Korrvu® packaging's unique design provides consistent protection even with repeated drops. |
Korrvu® frames are assembled just-in-time, so they can be stored flat, reducing space needed for packaging supplies by 90 percent. "Korrvu® suspension packaging has allowed us to clear away shipping materials from three warehouse bays, totaling 1,800 cubic feet, and use them for product storage," said Cosens. "The decrease in materials has also eliminated the clutter from manufacturing, receiving and handling areas."
At the packaging station, the Korrvu® suspension frame is assembled and placed in the bottom of the shipping container to suspend the Hyfrecator Plus® unit. The top frame is placed over the product, fully suspending it between two strong, flexible low-slip films. The box is closed, creating tension to hold the surgical unit securely within the suspension windows and away from potentially damaging impacts and other shipping hazards.
Since the switch to Korrvu® packaging, shipping damage complaints have been reduced to zero on shipping volume averaging 500 fragile electrosurgical devices per month. Also, Korrvu® packaging is recyclable and reusable, which takes the burden of proper disposal away from CONMED/Aspen's clientele.
"We had already been using Sealed Air's packaging materials to ship our electrosurgical devices to international destinations since the 1970's, said Cosens. "By applying Korrvu's suspension packaging design to the Hyfrecator® product line, Sealed Air continues to offer us the most durable, economical and practical solution in packaging materials."
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