Sustainability Within Medical Device Molding

Sustainability is critical to staying relevant in the medical device manufacturing industry, particularly given the prevalence of disposable end products. Plastic remains the most practical material for most one-time use medical devices, making it imperative to focus sustainability on the manufacturing process. Clients and customers expect a commitment to sustainability and seek assurance that we have taken all possible steps to reduce our carbon footprint.

“A good sustainability program makes economic and social sense,” according to local (Erie, PA) Sustainability Expert and Consultant, Kurt Duska. Duska has worked in the plastics injection industry for 45 years, including the last 20 years focused on engineering sustainability solutions for manufacturers, including Plastikos.

“In a world where plastic has a bad reputation,” Duska asserted, “Plastikos is a leader in environmental responsibility.” At Plastikos and Plastikos Medical, we employ many strategies to improve sustainability outcomes in the medical sector.

METRICS

We use a standard set of metrics to keep our sustainability efforts optimized and on track. Overall Equipment Efficiency (OEE) is a critical indicator to evaluate key operational factors such as:

Our current plant waste reduction goal is 75%, and we are nearing this benchmark at 74%. Our long-term objective is to achieve 100% recyclability. Monitoring these metrics enables us to assess progress and identify areas for improvement in sustainability.

EFFICIENCY INVESTMENTS

“Sustainability doesn’t come by accident,” says Duska. “You must have a plan for success through an ingrained corporate mission.”

We have integrated formulas to calculate kilowatt hours per part produced. Facilities inherently carry overhead energy demands, including HVAC and energy-hungry HEPA filtration systems. We must run our presses as efficiently as possible to mitigate energy waste. We ensure that presses operate efficiently with precise temperature settings, so we are only sending energy to the presses when they are actively producing quality parts.

Automation has been a key component to improving the Company’s sustainability by reducing labor and energy consumption. Plastikos Medical operates lights-out during second and third shifts, minimizing energy use while maintaining productivity with autonomous machines.

Additionally, we invested in strategic grinders that reduce waste and facilitate more efficient recycling. Reduction of size and bulk of large parts or runners allows for increased density of recycled material as well as improved logistics for shipping and viability of recycling. The denser recycled material is also more aptly accepted for recycling because it’s clean, well labeled, and ready to go into the next molding machine.

MINIMIZING EXCESS MATERIAL

Sustainability initiatives are also implemented in the tool design and engineering stage, material handling, and post production recycling.

By leveraging advanced tools, equipment, and continuous improvement projects, we aim to make every pellet count. Ideally, the goal is zero scrap leftover through use of a direct valve gated mold, eliminating runners and gates. Depending upon the geometries of a mold, this isn’t always an option. Regrind material cannot be used in medical applications. Through a diverse customer base at Plastikos, we repurpose high-quality, one generation heat history materials for non-medical applications while maintaining stringent quality control standards for high performance products outside of the medical space.

Duska added, “Plastikos labels, stores, and handles scrap properly and it makes a huge difference in diverting scrap from the landfill. A sustainability program doesn’t have to be difficult to run or hard to manage and if it’s done right, it should be profitable.”

Many years of experience with sustainability initiatives have allowed us to amplify the efforts through tightly monitored metrics, automation, material handling, and engineering tight-tolerance medical devices. As sustainability remains a top priority for medical device customers, we continue to deliver responsible, high-quality manufacturing solutions.

“I consider Plastikos a top company for technology, communication, and environmental stance,” Duska continues. “It’s a top-to-bottom program interested in having the least negative impact on the environment.”

About the Author:

John Wiliams, II serves as a Molding Manager & Jr. Partner in Plastikos & Plastikos Medical in Erie, PA. A graduate of the Plastics Engineering Technology program at Penn State Behrend, John has held diverse roles in Research and Development, New Product Development, Formulation and Compounding, and most recently Manufacturing Management in both Medical and Advanced Scientific Injection molding.
John is passionate about Continuous Improvement, Operational Excellence, and new and emerging technologies for the Injection Molding Industry. He and the Plastikos Team have developed advanced automation solutions to accommodate production volume and the growing demand for precise cavity separation through innovative End of Arm Tooling capabilities.

Beyond manufacturing, John also leads many internal safety training initiatives, most recently earning the Companies the MAPP Safety Achievement Award, among numerous other Safety Accolades.

Committed to education and workforce development, John is actively involved in regional STEM outreach programs, participates in educational group tours, and is a dedicated member of a peer group through the Center of Family Business at Penn State Behrend.

Special thanks to contributing expert, Kurt Duska. Duska started up numerous recycling programs, including those at large medical facilities such as Cleveland Clinic and is known for his hands-on, dumpster diving approach to identifying sustainability solutions. His company has been named the Environmental Company of the Year and received the PA Governor’s Award for Environmental Excellence. Duska offers waste stream audits focused on manufacturing scrap, obsolete products and rejected items.