Dye penetration testing is one of the primary methods used to verify seal integrity on medical blister trays. It detects micropores, cracks, and incomplete seals that are not visible to the naked eye — defects that could allow microorganisms, gas, or liquid to pass through the sterile barrier. This article covers what the test does,…
A weak seal on a medical blister tray is not a cosmetic issue. It is a sterile barrier failure. When the seal between the PETG tray flange and the Tyvek lid does not form a continuous, uniform bond, the package can leak during sterilization, storage, or transport — and the device inside is no longer…
In most manufacturing industries, “zero defects” is the stated goal. Every process improvement, every audit, every quality project points in the same direction — make the product right, make the process right, and do not ship anything out of spec. In medical blister packaging, we used to think that way too. After implementing ISO 13485…
Our booth N4-C209 at Medtec China 2026, Shanghai From September 1 to 3, 2026, the 20th Medtec China International Medical Device Design and Manufacturing Technology Exhibition took place at the Shanghai World Expo Exhibition & Convention Center. Our team at Honest Packaging exhibited at booth N4-C209, where we showcased our full range of medical packaging…
If you’re packaging a Class III implantable device — a pacemaker, a hip implant, a surgical mesh, an interventional heart valve — your regulatory consultant will tell you one thing almost immediately: you need a dual sterile barrier system. A single blister tray with a Tyvek lid isn’t enough. You need two layers of sterile…
It’s a phone call we’ve gotten a handful of times over the years, and it always starts the same way: “Our trays came out of the gamma irradiator and they’re cracked. What went wrong?” The customer is frustrated, the lot is on hold, and in the worst cases, trays are already in the field and…
We get this question all the time from new customers: “What’s the actual difference between your medical blister trays and regular blister trays? Aren’t they both just heated plastic sheets formed over a mold?” It’s a fair question. On the surface, a medical blister tray looks a lot like a blister tray for electronics, food,…
If you’ve ever held a 150cm interventional catheter in your hand, you know why packaging it is such a challenge. It’s long, it’s thin, it’s flexible, and the distal tip is a precision-engineered component that can be ruined by a single kink. Fold it too tight and you create a memory bend that affects catheter…
We learned this lesson the hard way about eight years ago. A new customer sent us a PETG tray design for a surgical instrument, specified for gamma sterilization at 25kGy. We made the trays, shipped them, the customer sterilized them — and every single tray came out of the irradiator yellowed, brittle, and cracked at…
If you’ve ever walked into a Class 10000 cleanroom for the first time, you remember it. The air feels different — dryer, cleaner, with a faint hum of HEPA filters running 24/7. You gown up: hairnet, beard cover, sterile gown, gloves, booties. You walk through the air shower, feeling jets of filtered air blast lint…