A Turnkey Medical Device Outsourcing Partner for Single-Use Medical Devices
J-Pac Medical is the complete outsourcing partner for all your sterile medical device assembly, packaging, and sterilization.
J-Pac manufactures single-use, Class II & III sterile medical devices including, surgical devices, implantable textiles, and diagnostic consumables for both large and small OEMs. We manage your product realization through a robust ISO 13485 Quality Management System, giving you a complete medical device contract manufacturing solution.
The Right Medical Device Outsourcing Partner from Start to Finish
J-Pac recognizes that you are challenged to develop better products, achieve faster time-to-market, and lower total cost. Yet your resources are becoming more limited, requiring you to do more with less.
The back-end product realization processes required to launch a medical device are the single biggest cause of delays because they require complex and highly regulated processes that take more time than expected.
J-Pac’s medical device outsourcing model results in faster and less expensive product launches by executing the backend headaches of package design, sterilization validation, shelf life testing, and manufacturing scale-up in parallel to product design.
A Better Outsourcing Model for Better Results
Our expertise is in the back-end of product development. We know what needs to be done, how long it will take, and how it can be best integrates with your design process to reduce time and costs.
Dependable | Trustworthy | High Quality
Clear communication and collaboration are crucial to success. While you have a dedicated project manager who coordinates your program schedule, our experience has taught us that speed requires communication at multiple levels. We are an extension of your company and our process is designed to give you direct access to the hands-on people at J-Pac who get stuff done: engineers, quality specialists, and manufacturing management.
Medical Device Outsourcing Capabilities and Expertise
Unlike other medical device contract manufacturers, our capabilities and expertise are not beholden to any one medical device technology. Our expertise is applicable to most any single-use medical device.
- Experience serving large and small OEMs
- ISO 13485:2016 certified
- FDA registered
- Class 7 and 8 cleanroom assembly
- Dryroom for bioabsorbables
- Medical device packaging design and validation to ISO 11607
- Sterilization validation
- Shelf life validation
- Manufacturing IQ/OQ/PQ
- ERP traceability and lot control
- In-house tooling
- In-house package thermoforming
- 3D printing
- Manufacturing automation
- Supply chain management
- Lean manufacturing
- ERP system
- Broad array of assembly processes
- Broad array of packaging formats including rigid and semi-flexible packaging, pouches, mounting cards, and gas flushing
- Label design
- Dual sourcing and nearshoring
- Raw material and finished good inventory management
Medical Device Assembly & Packaging Products
Our capabilities apply to a broad spectrum of consumable, single-use medical devices comprised of multiple plastic and metal components, assembled, tested, packaged, and sterilized.
Learn more about medical device packaging, validation, and design by reading a few of the most common questions we hear from our customers.
Do orthopedic implants need to be double packaged?
Double barrier thermoformed trays that nest into each other. Each tray will be sealed with Tyvek.
There is no regulatory requirement for double packaging orthopedic implants but there are several factors and requirements of ISO 11607-1 that influence the decision. Section 6.2.2 requires that the medical device package allow the product to be presented in an aseptic manner. While this does not require a double package design, some surgeons prefer to have a “belt and suspenders” approach where the inner package prevents any unnecessary contact while sitting in the sterile field. Additionally, many circulation nurses prefer the ability to transfer the device to the sterile field without waiting for someone in the field to take it out of the package. A double package design can facilitate this - often called “dumping,” “throwing,” or “dropping,” by OR nurses. Additionally, the standard section 6.1.1 requires that the package protect the safety of the user and patient. Some medical device implants have sharp features that may make a double package design desired. Lastly, the issue may come down to surgeon preference.
How do you validate medical device packaging?
Pre-validated, Double Barrier Packaging
Pre-validated nested double barrier packaging with custom urethane insert.
Packaging validation is complex. There are several processes that must be completed
- The manufacturing process to produce the packaging’s sterile barrier system must be validated. This requires an Installation Qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ) to be conducted on the manufacturing equipment.
- Packaging performance testing must be completed. This includes manufacturing and sterilizing under worst-case conditions and subjecting the packaging system to simulated distribution testing.
- A stability study must be completed and is typically done with both accelerated and real-time aging studies.
- Both the performance testing and stability study require tests for seal integrity and seal strength as well as an evaluation of product protection.
Does J-Pac perform post-thermoforming customization of medical grade trays?
Catheter Tray Package
A surgical catheter packaged in a thermoformed tray. The tray was designed with a clear lid that snaps into place. The customer wanted the tray to be pouched.
Thermoformed medical device packaging trays are customized to incorporate various types of venting to support lyopholization processes and/or Eto processing of resorbable polymers. Additionally, reverse flanges can be provided for large trays that are designed to accommodate heavy materials.
Let’s Get Started.
A conversation with J-Pac is your first step to having a manufacturing partner you can count on.