Simulation analysis offers a nuanced understanding of packaging dynamics, including factors such as material thickness, form factor, and failure points. Through virtual modelling, engineers can identify opportunities for lightweighting and material reduction, effectively reducing the product's environmental footprint. Additionally, simulation enables the exploration of alternative materials and design configurations, providing valuable insights into potential sustainability improvements.

Nic Hunt, head of sustainability, Nelipak Healthcare Packaging, shares how simulation testing is driving sustainability in medical packaging.

PPS resin is a high-performance engineering plastic. Key benefits are heat and chemical resistance, mechanical strength, and flame retardance. Applications include electrical components, electric vehicles, electrical and electronic devices, and housing-related parts. Applications continue to broaden. Toray decided to boost capacity at Toray Advanced Materials Korea to cater to a projected 6% growth in annual global demand for PPS resin compounds.

One notable application of simulation in medical device packaging is the optimisation of thermoformed plastics. By digitally modelling packaging designs and conducting virtual evaluations, stakeholders can assess the viability of sustainable packaging solutions before committing to physical production. This approach not only accelerates the design process but also minimises resource consumption and waste generation associated with traditional trial-and-error methods.

Toray Advanced Materials Korea will supply PPS resin not consumed domestically to Toray Group compounding sites in the United States, China, Europe, Southeast Asia, and other regions as part of an effort to expand its global business.

Japan’s Toray Industries and Idemitsu Kosan plan to develop a supply chain for acrylonitrile-butadiene-styrene (ABS) resin based on biomass styrene monomer derived from biomass naphtha. Idemitsu will leverage the mass balance method to manufacture biomass styrene monomer that will be fed to Toray’s Chiba plant for polymerization of biomass-derived ABS resin starting in October this year. Both Idemitsu and Toray are striving to achieve carbon neutrality by 2050.

Toray Group is a comprehensive manufacturer of PPS not just for compounds but also for films and fibers. It is the world’s largest player in this field.

Recognising the urgency of this challenge, medical device packaging manufacturers are stepping up their efforts to enhance sustainability throughout their operations. This includes a heightened emphasis on packaging design optimisation, material selection, and waste reduction initiatives. By reimagining packaging solutions, these manufacturers aim to minimise environmental impact while maintaining the integrity and functionality of their products.

Stephen has been with PlasticsToday and its preceding publications Modern Plastics and Injection Molding since 1992, throughout this time based in the Asia Pacific region, including stints in Japan, Australia, and his current location Singapore. His current beat focuses on automotive. Stephen is an avid folding bicycle rider, often taking his bike on overseas business trips, and is a proud dachshund owner.

A key strategy in achieving these sustainability objectives lies in the adoption of simulation testing techniques. By leveraging advanced simulation technologies, such as in silico modelling, packaging engineers can evaluate the performance of various packaging designs without the need for extensive physical prototyping. This allows for faster iteration and optimisation, ultimately leading to more sustainable packaging solutions.

In conclusion, the incorporation of simulation testing is poised to revolutionise the way medical device packaging is designed and optimised for sustainability. By embracing innovative technologies and methodologies, manufacturers can pave the way for a more environmentally conscious future while delivering high-performance packaging solutions that meet the evolving needs of healthcare providers and patients alike.

Toray Advanced Materials Korea Inc. plans to increase annual production capacity for Torelina polyphenylene sulfide (PPS) resin by 5,000 tonnes at a plant in Gunsan, Korea, from December 2024. The Toray Group’s combined PPS manufacturing capacity at this facility and the Tokai Plant in Aichi Prefecture, Japan, will thereby rise to a world-leading 32,600 tonnes/year.

Moreover, simulation-based optimisation extends beyond the design phase to encompass the entire lifecycle of medical device packaging. By simulating transportation, storage, and end-of-life scenarios, manufacturers can identify opportunities for further waste reduction and environmental stewardship. For example, optimising package dimensions and configurations can minimise storage space requirements and transportation emissions, while also facilitating recycling and disposal processes.

Ultimately, the integration of simulation testing into the packaging design process represents a paradigm shift in sustainability efforts within the medical device industry. By harnessing the power of virtual modelling, manufacturers can drive meaningful reductions in waste, energy consumption, and environmental impact. Simulation empowers stakeholders to make informed decisions based on quantifiable data, ensuring that sustainability objectives are achieved without compromising product quality or safety.

Toray Industries and Idemitsu Kosan are teaming up to produce biomass-derived styrenic resin, while Toray is adding capacity for PPS engineering resin.

Furthermore, simulation allows for scenario testing and sensitivity analysis, enabling manufacturers to anticipate and mitigate potential issues before they arise. By simulating real-world conditions and stressors, engineers can fine-tune packaging designs to ensure optimal performance and durability. This proactive approach not only enhances sustainability but also improves product reliability and customer satisfaction.

As sustainability continues to take centre stage in the medical industry, simulation offers a powerful tool for driving positive change and shaping a more sustainable tomorrow. With continued investment in simulation-based research and development, the medical device packaging sector can lead the charge towards a greener, more sustainable future for healthcare worldwide. The adoption of simulation testing represents not only a commitment to environmental stewardship but also a strategic investment in long-term competitiveness and resilience in an increasingly sustainability-focused marketplace.

A concurrent move will be to expand production of sodium hydrogen sulfide, a key raw material for PPS resin. Toray would thereby solidify its position as a cost-competitive, integrated manufacturer of everything from raw materials through resins.

Toray’s ABS resin is used in a variety of industries such as automotive, consumer electronics, and medical devices, for which it offers transparent grades.

In today's rapidly evolving healthcare landscape, sustainability has emerged as a critical focal point, particularly in industries reliant on plastic packaging. With billions of pounds of healthcare plastics being produced annually, the environmental impact of single-use plastics in the medical sector is undeniable. As the global community shifts towards more sustainable practices, the medical device and pharmaceutical sectors are facing increasing pressure to address their environmental footprint.