Prent was recently honored with the only 2010 WorldStar awarded to a medical package. This is our 13th WorldStar Award from the World Packaging Organization. The winning thermoformed design is helping Cook Urological significantly reduce packaging expenses by slashing tooling cost, per package costs and assembly costs. Universal Package Accommodates Both Current & New Devices Prent’s universal thermoformed clamshell accommodates 35 different Nitinol Basket product line options, including two different handle configurations. The baskets are used for urinary tract stone manipulation and removal. “As Cook continues making refinements in its medical device line, our universal package will help them easily accommodate both existing and new devices, including those with different handles, triggers and product configurations,” explains Joseph T. Pregont, Prent Corporation President and CEO. One-Piece Clamshell Tray Saving Costs Three Ways “Our design is also helping Cook reduce its packaging costs three ways,” he explains. “First, the one-piece design is cutting tooling costs because it is thermoformed using just one tool—rather than separate tools for trays and retainers. “Second, we cut the cost per package by more than 25% with the one-piece design. Third, less assembly time is now required,” points out Pregont, “since the one-piece clamshell can be loaded faster.” In addition, pouch abrasion is eliminated due to the design and location of a small, strategically placed fold-over hinge. Design Solves Loading & Unloading Issues The one piece design—coupled with four undercut features inside the circular cavity—has improved the ease and control of loading and unloading the delicate spiral medical devices. The undercuts also reduce product damage and prevent the medical device from popping out of the package or out of the operating room’s sterile field. “These were some of our biggest concerns because damage during loading and unloading was previously a common occurrence. I think the WorldStar judges agreed that our solution to the problem was pretty unique,” explains Pregont. ★ XXXX Issue No. 43, 2011 PAGE 1 Prent Wins Only 2010 WorldStar Awarded to a Medical Package IT’S A WINNER! The winning thermoformed design is helping Cook Urological significantly reduce packaging expenses by slashing tooling cost, per package costs and assembly costs. ★ ★ ★
Transcript
Prent was recently honored with theonly 2010 WorldStar awarded to amedical package. This is our 13thWorldStar Award from the WorldPackaging Organization.
The winning thermoformed design ishelping Cook Urological significantlyreduce packaging expenses by slashingtooling cost, per package costs andassembly costs.
Universal PackageAccommodates BothCurrent & New DevicesPrent’s universal thermoformedclamshell accommodates 35 differentNitinol Basket product line options,including two different handleconfigurations. The baskets are usedfor urinary tract stone manipulationand removal.
“As Cook continues makingrefinements in its medical device line,our universal package will help themeasily accommodate both existing andnew devices, including those with
different handles,triggers and productconfigurations,”explains Joseph T.Pregont, PrentCorporation Presidentand CEO.
One-PieceClamshell TraySaving CostsThree Ways“Our design is alsohelping Cook reduce itspackaging costs threeways,” he explains.“First, the one-piecedesign is cutting toolingcosts because it isthermoformed using justone tool—rather thanseparate tools for traysand retainers.
“Second, we cut thecost per package by more than 25%with the one-piece design. Third, lessassembly time is now required,” pointsout Pregont, “since the one-piececlamshell can be loaded faster.”
In addition, pouch abrasion iseliminated due to the design andlocation of a small, strategically placedfold-over hinge.
Design Solves Loading &Unloading IssuesThe one piece design—coupled withfour undercut features inside the
circular cavity—has improved the easeand control of loading and unloadingthe delicate spiral medical devices. Theundercuts also reduce product damageand prevent the medical device frompopping out of the package or out ofthe operating room’s sterile field.
“These were some of our biggestconcerns because damage duringloading and unloading was previouslya common occurrence. I think theWorldStar judges agreed that oursolution to the problem was prettyunique,” explains Pregont. �
Corporation2225 Kennedy Rd.P.O. Box 471Janesville, WI 53547-0471
RETURN SERVICE REQUESTED
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XXXX Issue No. 43, 2011
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Prent Wins Only 2010 WorldStar Awardedto a Medical Package
Nearly a decade ago, the industry standard forkit trays often made it difficult for medicalpersonnel to use. It could be a struggle tomaintain a sterile field on uneven surfaces,frequently encountered in outpatient bedsidesettings. Prent‘s solution was to combine thesterile field and tray into one integrated unit byRF sealing the tray to the wrap. The mergedprocedure tray and drape gave medicalpersonnel a combined sterile product andpackage (which provided stability and integrityfor the instruments), helped simplifyprocedures, saved time and money, plusallowed them to more fully concentrate on theprocedure and patient.
Prent’s design challenge was to contain andprotect a variety of catheters and dilators
without the use of a retainer or protective tube.The product also needed to be highly visibleand easily removed by a physician. In the end,the design for the Universal Catheter Tray gavethe customer increased flexibility to use the trayfor a variety of products, plus saved thecompany money.
RADIOACTIVEIMPLANT TRAYS
BENEFITS: Trays act as aprotective, safe workstation.
Prent’s thermoform package solution is nowchanging the way prostate cancer radiationtreatment is delivered worldwide. Thanks to asterile pewter case with inner plasticpresentation trays, the new design presentsdelicate radioactive products to the surgeon ina safe, convenient and properly orientedmanner. The package is composed of fourdifferent trays that function as an integratedworkstation for the assembly, shipment anddispensing of pre-dosed irradiation strands.
MRI TUBE SET
BENEFITS:Package + Device =Medical Product
When our customer developedan MRI Tube Set for their suiteof breast care products, thechallenge was to not only developa package that would present theproduct to the end-user and attach
snugly onto the MRI cart, but most importantly,the package had to contain, manage anddispense 30 feet of tubing used to connect theMRI to a computer located in another room. Inaddition, the package had to be so simple theoperator could intrinsically understand how tomanipulate both ends of the tubing, dispense itwith a free motion, and not worry abouttangling or kinking the tube. Prent’s innovativetwo-piece design is a great example of how“Package + Device = Medical Product.”
Prent’s 40-inch, one-piece tray design holds andprotects a series of 10 product lines. A small
clamshell lid protects the delicate catheter tip,while the larger lid keeps a guide wire andcatheter handles in place. The clear thermoformpackaging allows physicians to easily identifyproducts prior to opening the package. As aresult, they are able to visualize the sequence ofthe device assembly, as well as keep allcomponents organized in the sterile field whilepreparing for the procedure. �
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XXXX Issue No. 43, 2011
PAST WORLDSTAR WINNERS
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Prent is proud to have won13 WorldStar Awards formedical packaging, morethan any other company inthe world. Here’s a look atsome of our past winners.
Package + Device = Medical Product
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PAGE 3
THINKING GREEN
Today, Prent’s process quality control follows the PDCA Cycle: Plan, Do, Check, Act.
The Cycle was originally developed in 1924 by Dr. Walter Shewhart, a pioneering statistician who developed statistical processcontrol at Western Electric. His work pointed out the importance of reducing variation in the manufacturing process.
Today we use the PDCA Cycle to coordinate continuous improvement efforts starting with careful planning, resulting ineffective action, and moving on again to careful planning.
DesignedIn-HouseWhen Prent madethe decision nearlytwo years ago toinvestigateadopting plasticpallets forwarehousing ourmassive rolls ofplastic filmmovingthroughout ourfacilities—webegan by lookingat existing
suppliers. While most made excellent pallets, none metthe particular requirements needed by Prent. And thus,we began the long process of custom designing ourown robust Prent Plastic Pallets.
Closed-Loop RecyclingThe Prent designed pallets are now part of a closed –loop program we have established with one of our rollstock suppliers. Each pallet is made from plastic,reinforced with metal and is 100% recyclable. Since weexpect the life of each pallet to be many years, weanticipate significant landfill reductions in the long run.
Enhanced Cleanliness & SafetyAn added benefit of this durable recyclable skid is acleaner work environment and a more stable method ofmoving our roll stock within our facilities. Payingattention to the little things ensures our systems andenvironment are the best they can possibly be.
Today, our in-house designed plastic pallets are non-
porous and resistant to bacterial contamination andpathogens. They also have features which minimizewhere dirt, particulates or other foreign material canaccumulate.
Greater FlexibilityOne of the most unique features of each pallet are thethree very deep cradles designed to accommodatemultiple combinations of rolls sizes. Each pallet canhold one large roll, two medium rolls or three smallrolls. This offers flexible storage configurations andmaximizes our warehouse space.
The FutureWe are now phasing-in the Prent Pallet Program andeventually hope all roll stock suppliers can ship to ususing only plastic pallets. In the future, there will benothing but plastic pallets in our facilities, resulting infewer trips to landfills. �
Professionals from around the world tuned into a recentvirtual seminar on “Trends in Medical Packaging”moderated by Norbert Sparrow, Editor-in-Chief of EuropeanMedical Device Technology.
Experts from Prent, DuPont and others discussed recent andforthcoming innovations in medical-grade packagingmaterials. Prent’s address focused on:
�Common packaging requirements requested by medical
device manufacturers
�The necessity of asking the right material questions
BEFORE developing a new package
�Concerns over pushing the limits of standard materials
�An overview of new medical material developments to
meet new requirements, including MEDEX 641.
Custom Designed Plastic PalletsReducing Waste and EnhancingCleanliness
Process Quality Control is ReducingManufacturing Variation
What Comes Around, Goes Around
The launch of Prent’s new MEDEX 641 medical grade packaging material and ourWorldStar Award generated a lot of buzz around the world. Here’s just some of the placesnews stories about Prent have appeared in the past several months:
CHECK: Review the test. Analyze theresults and identify what was learned.
ACT: Take action based on what was learned.If the change did not work, go through the cycleagain with a different plan. Use what waslearned to plan new improvements and beginthe cycle again. �
MEDTEC China 2011September 7-8, 2011
Intex Shanghai, Booth 715Shanghai, CHINA
GLOBALTRONICS 2011September 19-21, 2011
Suntecd Convention Center, Booth G17SINGAPORE
MEDICAL DEVICE PUERTO RICO 2011
October 20-21, 2011Puerto Rico Convention Center, Booth 517
San Juan, Puerto Rico
MD&M MINNEAPOLIS 2011November 2-3, 2011
Minneapolis Convention Center, Booth 918Minneapolis, Minnesota, USA
COMPAMED 2011November 16-18, 2011
Dusseldorf Exhibition Centre, Hall 08a/P10Dusseldorf, GERMANY
BIOMEDevice 2011December 6-7, 2011
San Jose McEnery Convention Center Booth 721
San Jose, California, USA
NEWS AROUND THE WORLD
PAGE 4
PUERTO RICO •
Benefit for Underprivileged Youth
Victor Nazario (Prent Puerto RicoPlant Manager) and Joel Chacon(Prent Sales Representative) teamedup with others in the medical deviceindustry to participate in a golfouting benefiting P.E.C.E.S., anorganization helping localunderprivileged youth. Pictured leftto right are Leo Solórzano (Nypro),Nazario, Chacon and Roberto Perez(COO, Pall Corporation).
Congratulations to TeamGallitos on your 2nd placeLittle League finish!!
Janesville employeesenjoy a summer cook-out inappreciation for nolost time accidentsthis past quarter.
Congratulations!
JANESVILLE •
Safety Cookout
Michigan State Tour
Recently touring Prent was a large and enthusiastic group of packaging studentsfrom Michigan State University. It was a great opportunity to meet these futurepackaging leaders!
New Manager for HumanResources Welcome to Christine Verstegen, Prent’s new Managerof Human Resources. She comes to us from USCellular, where she was their field and corporateHuman Resources Manager.
Christine says, “I’m thrilled to be here. I have felt sowelcomed. It’s very evident the sense of pride theemployees have about working for Prent.”
She wants everyone to know the Human Resourcesdoor is always open. “Please always feel free to comein and ask about anything you want. I am here to helpeveryone be successful,” Christine says.
Prent Malaysia employees have formed the “Prent Club” to promotecommunications, the spirit of cooperation and social interaction through formaland informal recreational activities—in line with Prent’s policy to encouragehealthy and energetic lifestyles. Already planned for the coming months are acommunity service project, blood donation campaign, jungle trekking, campingand more.
Pictured left to right are a few Prent Club members: Maisarah bt Ismail (SeniorHR Assistant), Ravindra Gurung (Assistant Line Leader), Sanjib Shrestha(Tooling Controller), Prent Club Chairperson Safarin Jaffar (Admin Assistant),Thye Zhi Lei (Assistant IT Developer), Joyce Kho (HR Officer), and Saiful NizamMasrom (Assistant Supervisor).
MALAYSIA •
Employees Form “Prent Club”
Richard Zhou, Prent China Operations Manager, recentlyspent several weeks at Prent’s World Headquarters workingwith manufacturing, quality assurance and productioncontrol personnel to transfer the latest practices in medicalpackaging to our Prent China facility.
“Like all Prent global facilities, our thermoforming machinesare imported from over Worldwide Machine Build facility inJanesville,” reports Zhou. “Therefore all our procedures and
processes are the same as Janesville. We also have many products which requiresecondary operations such as pad printing, hot stamping and more.”
This was Zhou’s first visit to the USA. “Janesville staff is like a big family,” notesZhou. “Manufacturing works very closely with QA and Design to ensureexceptional trays are produced with great efficiency. Everyone was very kind,helpful and willing to share their knowledge and experience with me.”
About 300 Prent Chinaemployees had fun during theannual company excursion toHappy Valley, a hugeentertainment center inShanghai. Everyone enjoyed thebeautiful weather and rides. Itwas a relaxing and refreshingbreak from busy work schedules.
CHINA •
Training For Best Practices
Employees Have Fun atShanghai Park
A course of “Basic First Aid and CPRTraining” was recently held at Prent Malaysia,in collaboration with the Civil DefenseDepartment. The program equippedemployees to provide timely care to injuredpersonnel. Pictured delivering CPR is HangLee Choo (QA Supervisor) and standing is aCivil Defense officer.
Ready forEmergencies
Tooling Technician FuYinGang(right) puts out a fire ignitedby the Fire Dept officer (left)during Prent China’s annualfire training. In addition tolearning how to use a fireextinguisher, employeespracticed evacuating the plantand reviewed the “dos anddon’ts” of fire emergencies.
Never Taking Safetyfor GrantedNew VP of Materials
Management andProject EngineeringMitch Benson has been promoted to Vice President ofMaterials Management and Project Engineering. Inaddition to closely monitoring the volatile plasticsmarket, Mitch is leading several new projects aimed atreducing costs and streamlining operations. Hisresponsibilities include Purchasing, Production
Control/Planning, Logistics and Manufacturing Engineering. Previously, Bensonserved as Director of North American Operations.
Mitch Benson
Christine Verstegen
Prent was recently honored with theonly 2010 WorldStar awarded to amedical package. This is our 13thWorldStar Award from the WorldPackaging Organization.
The winning thermoformed design ishelping Cook Urological significantlyreduce packaging expenses by slashingtooling cost, per package costs andassembly costs.
Universal PackageAccommodates BothCurrent & New DevicesPrent’s universal thermoformedclamshell accommodates 35 differentNitinol Basket product line options,including two different handleconfigurations. The baskets are usedfor urinary tract stone manipulationand removal.
“As Cook continues makingrefinements in its medical device line,our universal package will help themeasily accommodate both existing andnew devices, including those with
different handles,triggers and productconfigurations,”explains Joseph T.Pregont, PrentCorporation Presidentand CEO.
One-PieceClamshell TraySaving CostsThree Ways“Our design is alsohelping Cook reduce itspackaging costs threeways,” he explains.“First, the one-piecedesign is cutting toolingcosts because it isthermoformed using justone tool—rather thanseparate tools for traysand retainers.
“Second, we cut thecost per package by more than 25%with the one-piece design. Third, lessassembly time is now required,” pointsout Pregont, “since the one-piececlamshell can be loaded faster.”
In addition, pouch abrasion iseliminated due to the design andlocation of a small, strategically placedfold-over hinge.
Design Solves Loading &Unloading IssuesThe one piece design—coupled withfour undercut features inside the
circular cavity—has improved the easeand control of loading and unloadingthe delicate spiral medical devices. Theundercuts also reduce product damageand prevent the medical device frompopping out of the package or out ofthe operating room’s sterile field.
“These were some of our biggestconcerns because damage duringloading and unloading was previouslya common occurrence. I think theWorldStar judges agreed that oursolution to the problem was prettyunique,” explains Pregont. �
Corporation2225 Kennedy Rd.P.O. Box 471Janesville, WI 53547-0471
RETURN SERVICE REQUESTED
PRE-SRT STDU.S. Postage Paid
PAIDJanesville, WI
Permit No. 914
XXXX Issue No. 43, 2011
PAGE 1
Prent Wins Only 2010 WorldStar Awardedto a Medical Package
