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Thermoformed surgical trays are made with a large variety of materials. Each material possesses unique characteristics that make it highly suitable for very specific surgical instruments. Often, manufacturers select these materials based on how well they are able to endure heat, chemical exposure, and impact as well as their general rigidity.
Polycarbonate (PC)
This clear plastic material is especially valued for its high impact resistance, strength, and clarity. Because of these very qualities, polycarbonate is often used in instrument trays that require both durability and visibility to allow for easy identification of the contents. It is also very resilient to sterilization processes like autoclaving.
Acrylonitrile Butadiene Styrene (ABS)
Acrylonitrile butadiene styrene or ABS, is extremely popularized due to its balance of toughness and ease of thermoforming. It is regularly used in medical trays for its chemical resistance and capability to withstand moderate temperatures. ABS is particularly well suited for containing sterilizable medical instruments, equipment, and devices as it does not easily break down or lose structural integrity under heat or chemical exposure.
Polypropylene (PP)
Polypropylene is an extremely versatile thermoplastic resin that is prized for its resistance to chemical and heat. It is often employed in medical trays for sterilization applications and can endure up to 121°C (250°F) during autoclaving without warping. Medical professionals appreciate thermoformed polypropylene trays due to their lightweight build yet robust form. This makes them portable as well as highly durable.
High-Density Polyethylene (HDPE)
High-density polyethylene is known for its strength and rigidity. It also has a stellar reputation for its resistance to a wide variety of chemicals. Commonly, medical professionals use HDPE trays in settings where exposure to harsh chemicals is a definite possibility. Its durability as well as its inability to absorb moisture makes it ideal for packaging in sterilization.
Thermoformed PVC
PVC, or polyvinyl chloride, is renowned for its versatility and cost-effectiveness. Medical professionals employ thermoformed PVC trays for single-use applications in procedures where flexibility and quick heat sealing are critical. PVC's softness makes it very accommodating for custom-shaped packaging to comfortably fit medical items.
Plastic trays come in various designs tailored toward the trays’ intended use and clientele. These designs cater to different surgical specialties while optimizing for efficiency, organization, and sterility.
Custom Instrument Trays
These are specially designed trays that are tailored to hold specific sets of surgical instruments for particular procedures. Their main selling point is that they allow for quick access during surgery. What’s more, they minimize the need for sterilization throughout the process as each tray is used for a specific procedure.
Separating Compartment Trays
These trays are designed with multiple compartments of varying sizes to segregate and organize different surgical instruments. The larger compartments typically hold bigger instruments while the smaller ones separate sutures, scissors, or forceps. These trays are ubiquitous in hospitals and surgical centers that perform a wide variety of procedures and require efficient instrument organization.
Stackable Trays
Stackable trays provide extra storage solutions with multiple trays designed for stacking on top of each other. They tend to come with perforated bases and absorptive columns to allow for good air circulation and equalize the trays’ temperatures during sterilization. These trays conveniently save space in sterilization units and storage cabinets while still maintaining the required sterile conditions.
Single-Use Procedure Trays
Single-use procedure trays are prepackaged and, as the name says, designed for use in one surgical procedure. They contain all the necessary sterilized instruments and supplies for a particular procedure. Examples include wound dressing trays, catheterization trays, and more. Their very helpfulness lies in their time-saving factors as they eliminate the need to gather items individually before surgery.
Specialty Trays for Sterilization
These trays are purposely made to hold items like tubes, catheters, and other devices that are not packaged individually but require sterilization. They help keep these items in an upright position and allow for the even circulation of steam or sterilizing agents to guarantee that all items are properly sterilized.
When choosing the right medical-grade plastic packaging, there are several things that need to be kept in mind. One must consider factors such as materials, sterilization compatibility, and tray customization options as they all have a relative impact on the quality of the tray.
Durability and Strength
There is no denying that durability and strength play a significant role in the overall performance of the tray, especially if it is transported or utilized on a daily basis. Pick trays that are made from durable materials such as polycarbonate, polypropylene, and PVC, as these are impact-resistant and will provide long-term use. You might also want to consider auto clave ability. Select trays that can withstand the rigors of sterilization processes like autoclaving or ethylene oxide sterilization without any distortion or loss of structural integrity.
Compatibility with Sterilization Processes
Different sterilization methods have different effects on the trays. For instance, autoclave trays must be able to withstand high-pressure steam. In comparison, trays prepared for low-temperature sterilization methods, such as gaseous plasma, are typically made from more heat-sensitive materials. Therefore, it is imperative to select a tray that is compatible with the sterilization method most frequently employed in that particular healthcare facility.
Customization and Sizing
Another factor that needs to be considered is how the size of the tray corresponds with the instruments it holds. The tray chosen must fit the surgical instruments precisely to ensure orderly arrangement and easy accessibility during operations. You may also want to look into customization possibilities. Custom trays like those produced using injection molding can make use of specific layouts that cater to particular medical procedures. They help increase both operational efficiency and surgical safety by ensuring that all components are in their designated locations during usage.
Antimicrobial Properties
To increase infection prevention, some thermoformed trays come with added antimicrobial properties. These properties tend to inhibit the growth of bacteria and other pathogens on the tray surface. This is especially valuable in high-risk areas or for procedures that require an extra lens of infection control. Consider trays with permanent, beholden, or surface antimicrobial additions for an extra layer of safety.
Cost-Effectiveness
Finally, it is important for one to mind the costs. While this goes without saying, do not only consider the initial costs of the trays. Take a deep look at their long-term benefits, such as durability, resistance to wear and tear, and the overall potental decrease in replacement rates. Moreover, consider whether single-use trays may be more beneficial from an infection-control point of view versus reusable ones that may require more rigorous cleaning and maintenance.
Thermoformed plastic trays are used to transport and temporarily store instruments between cleaning, sterilizing, and storage. They protect these items from that damage as well as from contamination.
Plastic trays can be found in hospitals, clinics, surgeries, and other medical facilities.
While metal trays come with durability, thermoformed plastic trays steal the show with their lightweight. This makes them easier to handle. In addition, they are very flexible and versatile. Being plastic, they can also be manufactured in various customized shapes and sizes to optimally cater to clients’ needs.
Typically, a thermoformed plastic medical tray that is autoclavable and properly maintained, should last around 3 years. However, this can change depending on factors such as the environment it’s in, the frequency of usage, and care instructions for the tray. Make sure you keep it in the right conditions to increase its longevity.
Impact resistance protects delicate instruments within the tray from damage of any kind. It also protects those instruments from that damage caused by any external force. Lastly, it increases the long-term durability of the tray itself, making it ideal for medical environments characterized by constant movement.
Some materials, like polypropylene, are considered more environmentally friendly as they are indeed recyclable. However, certain types of thermoformed plastics may be more challenging to recycle. There is increasing development of eco-conscious production practices in the medical plastic tray industry.
