Multi-Cavity PETG Medical Blister Tray for Procedure Kit
This custom multi-cavity PETG medical blister tray is designed to organize and protect multiple components within a single sterile barrier. As shown, the tray holds a three-way stopcock with extension tubing, a small collection vial, two graduated syringes, and a plastic accessory clamp — each seated in its own precisely formed cavity with molded retention features.
The multi-cavity design keeps every component in its designated position, preventing movement, contact, and cross-contamination during shipping and storage. Manufactured from medical grade PETG in our ISO Class 7 cleanroom, this tray is designed to be heat-sealed with Tyvek lid material to form a complete sterile barrier system suitable for EO, gamma, or e-beam sterilization. The clear material allows visual verification of kit contents and component position without opening the package.
This is a typical multi-component interventional procedure packaging solution — the kind where every component has to stay in exactly the right place, through sterilization, international shipping, and hospital handling, until the OR team opens it aseptically.
Key Features
Specifications
| Material | Medical grade PETG (Eastar 6763 / SK 2008), also available in APET |
| Nominal Wall Thickness | 0.5 mm – 1.0 mm (customized per tooling design) |
| Color | Transparent clear (light blue tint optional on request) |
| Cavity Count | Multi-cavity (customized to your kit contents — as shown: 6+ cavities) |
| Seal Flange Width | 8 – 12 mm, compatible with Tyvek 1073B / 1059B / 2FS |
| Sterilization Methods | EO, Gamma (25–50 kGy with gamma-stabilized grade), E-beam |
| Production Environment | ISO Class 7 (Class 10000) cleanroom, ISO 13485 certified facility |
| Shelf Life | 1 – 5 years (validated per accelerated aging study) |
| Standards Compliance | ISO 11607, ISO 10993, FDA 21 CFR, EU MDR |
Typical Applications
This multi-cavity blister tray design is suitable for packaging multi-component medical procedure kits, including but not limited to:
- Infusion, transfusion, or IV access procedure kits
- Blood collection and sampling procedure sets
- Interventional procedure accessory kits (stopcocks, tubing, syringes, adapters)
- Anesthesia and regional anesthesia procedure packs
- Diagnostic and therapeutic drainage or aspiration kits
- Other multi-component medical devices requiring individual cavity retention within a single SBS
For longer devices such as catheters or guidewires that need to be held flat in a long channel, we commonly pair the blister tray with a custom mounting card that snaps into the tray cavity. If your device needs a secondary sterile barrier around the entire kit, we can also provide a matching sterilization pouch or bag as the outer package.
We also offer custom medical blister trays in single-cavity, dual-cavity, and multi-cavity configurations for a wide range of medical devices. Every tray is custom-formed to match your specific component geometry and kit configuration, with retention features designed for secure transport and smooth, atraumatic removal in the clinical setting.
Complete Sterile Barrier System
This blister tray is designed to be part of a complete sterile barrier system, not a standalone package. Depending on your product’s risk classification and sterile presentation requirements, we can supply the matching components:
- Die-cut Tyvek lids (1073B, 1059B, 2FS) heat-sealed to the tray flange for EO, gamma, or e-beam compatibility
- Sterilization pouches and bags (Tyvek bags, paper-plastic pouches, head bags, foil bags) as a secondary sterile barrier for higher-risk devices
- Die-cut mounting cards (PP or HDPE) for holding flexible or long components inside the tray cavity
- Custom printing on Tyvek lids or pouches for product identification and traceability
Why Choose Honest Packaging?
Frequently Asked Questions
Q: Can you design a custom tray for my specific procedure kit?
Yes. This tray was custom-designed for a specific multi-component kit, and we can design a completely custom tray for your exact component set. Send us the dimensions or actual samples of your devices, your sterilization method, and your quantity requirements — we’ll provide a free design review and quotation.
Q: What material do you recommend for gamma sterilization?
For gamma sterilization at 25 kGy or higher, we recommend gamma-stabilized PETG (Eastar 6763 gamma grade or SK 2008 gamma grade). Standard PETG can become brittle or crack after gamma exposure. Learn more in our guide to sterilization compatibility testing.
Q: What is the minimum order quantity for custom trays?
For custom-designed trays, the MOQ is typically 5,000 pieces after mold completion. We also offer smaller prototype runs (50–200 pieces) for fit testing and validation before mass production.
Q: Do you provide validation documentation?
Yes. We provide COAs, biocompatibility reports (ISO 10993), first article inspection, dimensional reports, cleanroom monitoring records, and full lot traceability. We also support IQ/OQ/PQ validation for your packaging process.
Q: Can you supply the complete packaging system, not just the tray?
Yes. We can supply the matching Tyvek lids, sterilization pouches, and mounting cards as a complete sterile barrier system, so you only need one supplier for your rigid and flexible packaging components.
Need a Custom Multi-Cavity Tray for Your Procedure Kit?
Send us your kit component list, drawings, or physical samples. Our engineering team will design a custom multi-cavity blister tray that holds every component securely, with optimized retention features and seal flange for your application.
