Medical Device Company Achieves Zero Damage with Custom Protective Packaging

The Challenge

Pain Points

• High damage costs: Average damage claim of $12,500 per incident
• Calibration sensitivity: Equipment required recalibration after any impact
• Regulatory requirements: FDA packaging validation requirements
• Global shipping: Units shipped to 45+ countries via various carriers
• Reputation risk: Damaged equipment undermined premium brand positioning

The Solution

Phase 1: Inner Pack Design

We engineered custom foam protection with high-density polyethylene foam, custom-routed cavities for exact product fit, designed for 2-inch free-fall drop protection with reinforced corner blocks rated for 50G impact.

Phase 2: Outer Container

Heavy-duty shipping container with 350# burst strength corrugated, reinforced corner posts, die-cut handles for manual lifting, and integrated pallet base.

Phase 3: Monitoring & Compliance

We integrated ShockWatch 25G impact indicators, TiltWatch Plus orientation monitors, and complete FDA compliance documentation including IQ/OQ/PQ validation protocols.

Results

Contamination Control

Metric	Before	After	Improvement
Damage rate	2.8%	0%	100% elimination
Damage claims	34/year	0/year	Total elimination
Claim costs	$425K/year	$0	$425K saved

Regulatory Compliance

• FDA inspection: Zero observations
• Customer audits: Zero findings
• Complete documentation audit-ready

Explore Our Protective Packaging Solutions

Ready to achieve zero-damage shipping? Learn more about our offerings:

• Protective Packaging - Custom foam engineering and shock protection
• Die-Cut Foams - Precision-routed foam inserts for sensitive equipment
• Packaging Materials - Heavy-duty corrugated and shipping containers

Conclusion

For high-value, sensitive products, protective packaging is not an expense, its an investment that eliminates costly damage, protects brand reputation, and ensures customer satisfaction.

Contact Country Innovation & Supply for protective packaging engineering.