Case Study: BMP Medical Optimizes Packaging with Shawpak

BMP Medical recently purchased a Shawpak medical packaging machine, as it was the right solution for their product.

The Challenge

BMP Medical is a world leading manufacturer and supplier of Tissue Grinders and understands the importance of seeking more efficient and cost-effective packaging solutions for their products. Their current packaging method, utilizing pre-made pouches that are 72sq/in size, was inefficient in terms of material usage and labor requirements.

The Solution

BMP Medical first met Shawpak at MD&M West Pack 2024 while seeking a small footprint thermoforming packaging machine. Shawpak’s compact 32-20 rotary thermoforming machine proved to be the ideal fit for BMP’s needs, offering the flexibility and efficiency required for their production process.

Shawpak's application engineers worked closely with the engineers at BMP Medical to design a unique thermoformed package to best suit the product while minimizing material usage. This also means more packs per case, reducing the cost in sterilization and shipping. This collaborative approach resulted in a package that was significantly smaller, 28sq/in, than the previous 72sq/in pre-made pouches, reducing material consumption by over 60%.

The Results

The implementation of Shawpak’s medical thermoforming packaging solution has provided substantial benefits for BMP Medical:

• Reduced Material Consumption: The smaller thermoformed package leads to a significant reduction in material usage, resulting in cost savings and a smaller environmental footprint.
• Increased Efficiency: The new packaging process will streamline operations and reduce staff from 4 per week to 2 over 1.5 shifts providing a significant cost savings. This will allow BMP Medical to increase production without additional labor.
• Improved Cost-Effectiveness: The combined reduction in material and labor costs significantly improves BMP Medical's overall cost-efficiency.

Customer Testimonial

‘’A lot of the processes at BMP are automated with heavy investment in recent years in robotic cells. The packaging of our Tissue Grinder product range has always been an area where we knew we could improve the efficiency by automating the packaging process. Over the years we have looked at various thermoform machines, but all were very large in footprint which prevented us from making the change.

While visiting the 2024 MD&M trade show in Anaheim CA we came across Shawpak and saw firsthand their unique Rotary Thermoform Machine; it was ideal for what we needed. Working with the Shawpak application engineers we quickly made prototype packages which looked great and gave us the confidence to move ahead with the machine purchase – 4 months later the machine and tool were complete and heading to our facility in Massachusetts.”

-Michael T. Faulkner, Chief Executive Officer & President, BMP Medical