How are medical packages designed for transport?

Medical equipment is often valuable, vulnerable and essential for training, diagnosis or treatment. Damage during transport can result in repairs, delays and downtime. Even a missing cable or damaged connector can render an entire system unusable.

Custom packaging does more than prevent movement and damage. We also create a clear layout, a logical unpacking sequence and a professional presentation. Each component has a fixed position, allowing users to see immediately whether the set is complete.

We applied this approach for Philips Healthcare, for example. Its training equipment was transported in wooden crates, creating a risk of damage and missing components. The appearance of the crates also failed to reflect the professional image of Philips. Together, we assessed the equipment, accessories and use during training sessions. We then developed professional flightcases with custom interiors. This allowed us to combine protection, completeness checks and presentation in one reusable solution.

There is no single standard that applies to every medical transport packaging solution. The relevant requirements depend on the device, transport route, mode of transport and risks encountered along the way. We therefore determine what is genuinely applicable for each project.

Standards for primary packaging or sterile barrier systems fall outside the scope of this article. Here, Faes focuses on reusable outer packaging for medical equipment.

We select materials based on the product’s weight, vulnerability, frequency of use and logistics process. A flight case is suitable for heavy equipment and intensive transport. A shock-resistant plastic case provides robust protection in a compact format. EPP is particularly useful when low weight, impact absorption and frequent manual handling are important.

We adapt the interior to the product’s shape, mass and vulnerable areas. This involves more than selecting the right foam. We also consider:

• secure fixation without placing unnecessary pressure on vulnerable components;
• fixed positions for cables, accessories and documentation;
• finger recesses and a logical unpacking sequence;
• immediate visibility of missing components;
• cleanable and replaceable interior parts.

We design the outer packaging and the interior as one integrated protective system.

Does your medical equipment need to arrive safely, complete and ready for use?

Let our Engineers assess the product, transport route and daily use. Together, we can determine which packaging solution is most suitable.

A well-designed transport package keeps the product securely in place and manages the forces generated during transport. We work according to four main design principles:

1. Targeted fixation: the product cannot move uncontrollably, while vulnerable components remain free from unnecessary pressure.
2. Appropriate cushioning: the interior is matched to the product weight and expected loads. Foam that is too soft may bottom out, while foam that is too hard transfers impacts almost directly to the product.
3. Safe handling: handles, wheels, closures and stacking features are selected according to the weight, route and user.
4. Intuitive use: components are easy to locate, remove and return to their correct position.

The result is not simply a standard case with foam, but a transport system designed to work in practice.

We assess the entire route: internal transport, loading and unloading, the journey itself, temporary storage and use at the destination. This reveals the risks the packaging needs to address.

A strong outer construction and a carefully engineered interior reduce the effects of impact and vibration. Seals and water-resistant materials can provide protection against dust and moisture. When a specific performance level is critical, we test the complete, filled packaging according to a programme that reflects the expected distribution environment.

Temperature-controlled transport for vaccines, medicines or biological samples requires a separate thermal design and validation process. This falls outside the medical equipment transport packaging discussed in this article.

For us, sustainability starts with a long service life. We design packaging for repeated use and, wherever possible, ensure it can be maintained, repaired and adapted.

We consider:

• replaceable interiors, closures, handles and wheels;
• modular designs that accommodate future product changes;
• avoiding unnecessary material and weight;
• efficient dimensions for transport and storage;
• materials that can be separated as effectively as possible at the end of their useful life.

The most sustainable solution is not automatically the lightest. It is the solution that provides the necessary protection while minimising damage, waste and replacement throughout its service life.

Reliable medical transport packaging is created by treating the product, route and user as one integrated system. At Faes, we first identify vulnerable components, accessories and operating conditions. We then determine the most suitable outer packaging, interior and acceptance criteria.

Where necessary, we produce a prototype and test the complete solution. We also consider maintenance, repairs and future product changes. This results in packaging that protects the equipment, creates order and makes everyday work easier.

Do you have medical equipment, an instrument set or a training system that is transported regularly? With information about its dimensions, weight, vulnerable components and transport route, our Packaging Engineers can provide targeted advice on a suitable custom packaging solution.