Posted by
Dr. O on
11/18/2011 1:58 PM |
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Our Minnesota senators and representatives on the Congressional Technology Caucus, Democrat and Republican, have signed a bipartisan open letter to FDA Commissioner Margaret Hamburg asking for, in effect, a streamlined, more flexible and transparent FDA approval process. Any time that Michelle Bachmann and Al Franken agree on something, the evidence of a problem must be overwhelming. Medical device companies are behind this effort but I would suggest that they perhaps look at some of their own processes, notably in the area of packaging requirements, and do a bit of streamlining and flexibility addition of their own. One of the things that’s made me crazy for years is the beloved Material Certification, Certificate of Compliance, or whatever it’s called at your company. I am going to take the controversial position that this document, a piece of paper without which our labels can’t be released to production, is, as my departed Grandpa would say, “about as handy as teats on a boar hog”.
The final straw that precipitated this tirade came earlier this week. We had produced a label qualification run for one of our customers and sent it over to them. The feedback we received was that everything went fine except we did not meet the requirement of packing them 1000 labels per roll, with double shrink wrap. Our crime/transgression? We only packed 500 labels per roll in the prescribed fashion. Why? Because they only ordered 500 for the qual run! We received an email informing us of the egregious oversight, asking for a Certificate of Conformance affirming that we would indeed pack them 1000 per roll when the production order was placed. Over the years we have shipped this customer lots and lots of labels, most of which were nicely packed 1000 per roll and double shrink wrapped. When more than 500 labels are ordered, of course.
My eldest son owns a company in Portland, OR, a wonderful city with 45 beer brewing operations within the city limits. He recently sent me an email exchange with a customer, who had called one of their practices ‘stupid!’. The email to his old dad read, “The good thing about owning your own business is that you can tell people to pull their head out of their ass”. His response to the critical customer was, “Free life advice: you will elicit a better response if you refrain from calling people stupid. Thanks, Erik”. Since I only own a wing tip of the Advanced Web Thanksgiving turkey, I will refrain from any name calling regarding the Certificate of Compliance requirement. I would ask however, that we take a look at just exactly what a COC/COM accomplishes in the goal of receiving the correct label component for your terminally sterilized package and being able to trace it if there is an issue. In my opinion it accomplishes nothing. Zero. Nada. We typically receive a print from our customer and do a ‘preflight’, a process by which we make sure we can access the label stock called out in the print, that the tolerances are correct, and that the label is produceable and repeatable. We already have a change agreement in place with most medical device customers swearing on a stack of Bibles with Torahs and Korans interspersed in the stack, that we will change nothing unless we have written authorization from the medical device customer. What these certs basically do is say, “Yup, per our agreement this is indeed the stock, ink colors, etc. that you called out on your print. It’s exactly like the 63 other lots of this same label that we’ve sent you over the past five years and nothing has varied”. In addition to this invaluable document, which is normally printed out and in an envelope stuck to the outside of a carton (or turkey?), our manufacturing lot number, the key to the critical traceability component, is inside the core of every roll, on the carton, and in every piece of paperwork relating to the shipment. In the lean/value added process scheme of things, does this scrap of paper, the COC/COM, add any value to the label product? Does it insure correct material? Do we mobilize a detailed traceability process for each label order before the cert is issued, tracing the paper back to Aspen tree #435 on the SW of the SE 40 acres, Section 18, Town of Oulu, Bayfield County, Wisconsin? My answer to those questions would be 1) No, 2) Nope, 3) Hell no!. Some of our more proactive customers agree with that assessment and have dispensed with the cert process for every single order and instituted a ‘Technical Agreement’ in it’s place. This is a legalese filled document, signed by both companies with sub headings such as Supply of Products and Related Information, Validation Requirements, Product Quality Obligations, and Quality Systems. In a nutshell it says that the device company will provide us with prints and specifications, that we will mutually review and agree upon said prints and specs, and that we will not deviate from the print unless there is agreement in writing. It is basically an overall Certificate of Conformance/Compliance.
I’ve tried to shoot holes in this technical agreement process but have been unable to. Using our job number we can trace label stock, ink, and our machine process back to vendor master rolls, ink batches, and which operators at AW performed each and every operation down to packing the box. As mentioned earlier, this number is all over the place on every label shipment. If there is an issue of any sort, that number is used to access the entire job record including label retains. How does generating a redundant piece of paperwork add to the value of the labels or the package they go on? Do ya think maybe it wastes the time of customer service, final pack, shipping, receiving, incoming inspection, and quality personnel at both our plant and our customer? Precisely what function does certifying each and every batch perform? Have perfectly good labels needed on the production line ever sat in incoming inspection because someone misplaced the cert? If a batch is certified and there is indeed an error (humans involved here folks) will there be fines, suspensions, and a visit from the CAPA Police? Those are questions that need to be asked, considered, and honestly thought about. When I run through that question set I come up with the conclusion that the whole process is stu…….oops, poorly thought out.
I know that the Certification windmill will never succumb to my Don Quixote-like tiltings. This very day we will dutifully generate some BS document, affirming our intent to rewind 1000 labels per roll (maybe also asking for deviations on any future engineering/qual runs signed and notarized by multiple company officers) and there will be muttering and snide comments made. But if we are looking to the FDA to streamline their process we should also embrace the lean philosophy and do some common sense modifications of our own procedures. Relying on the checks and balance of our upstream vendors quality systems, all of whom we have audited, qualified, and yes, certified, would be a great step and send a message that we are serious about getting devices to market quickly and safely.
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Posted by
Dr. O on
10/5/2011 2:25 PM |
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We attended a medical device manufacturing event in San Antonio a couple weeks back. The organizers were either smart or sadistic when they chose the venue, depending on your point of view. We were held captive in a golf resort northwest of town, a $40 cab ride (one way) from the earthly pleasures of Riverwalk. Early morning attendance was greatly increased but unless you wanted some high end retail experiences the location was a bit sterile.
When we arrived on Sunday we were also informed that, on a NFL Sunday, the bar did not open until 4pm and did not have NFL Sunday Ticket. It was a sullen and demoralized crew that watched the exciting Jacksonville/Jets game. Still, we were there for the advancement of medical device manufacturing knowledge and intelligent discourse on the issues. It was a fairly high level group, yours truly excepted, but most of the attendees were well aware of labeling issues for terminally sterilized packaging and one of the issues that everyone has is the lack of label real estate.
Our record at Advanced Web is 27 languages on one label. My guess is that it will increase rather than decrease in the future. Symbols, both EN 980 and ISO 15223 can help with the space management, translation costs, and lengthy lead times associated with the translation process. As most people know, a company can create and use its own symbols as well as long as they are explained, in 27 languages of course, in the IFU.

The printed IFU itself might go away when E Labeling is finally allowed in the EU, a rare instances where the FDA is ahead of the innovation curve on this type of issue. As the Medical Device Directive and the Packaging Waste Directive trade body blows, toe to toe in the EU arena, I can't help but wonder the impact on labeling when this logical, cost effective, and green alternative to pitching a 48 page booklet in the dumpster is authorized. My guess would be that with the information being electronic or on a disk, more information will be needed on the package labeling.
Unique Device Identification is another requirement that is coming down the pike. The Global Harmonization Task Force released its final rule on global UDI about 2 weeks ago. No matter how the program is implemented it will require valuable label real estate to implement. Other standardization efforts are in the works as well. There is an initiative in ASTM to come up with a standard labeling format for arthroplasty. A guy I know even wrote an article in PMP News on the topic this month. Once again the content of the label will need to be manipulated, in both instances for well thought out and progressive reasons, but nonetheless it's certain to use up more label space.
So what's the answer? Heck, I don't know, I'm just a label guy who kicks out a blog now and then. One thing would be more symbols and more standardized symbols. There are plenty of things that are consistent across the board whether you are making pacemakers or spinal implants. Size matters as well. All of the devices I'm discussing are used by medical professionals; grandma doesn't have to read the verbiage with her +4.00 cheaters. Six point type is readable, especially if you use a good, readable font such as Helvetica. Stay away from the serif typefaces, the cute little fonts favored by more artistic types, with curly Q's and lines that vary in thickness throughout the stroke of the character.
Adding real estate is another solution. 'They ain't makin' any more land' is the common wisdom when you're complaining about the cost of real estate acreage but it's not true with label acreage. The size of the label on the package can be maxed out. On a four foot long introducer lead this is not a problem, on a relatively small pacemaker package it can be, which is a key issue with any standardization that is applied across the board.
Things such as expanded content labels, the little accordian fold booklets seen on many small packages, are one way to increase space for label verbiage. Lots of questions but minimal answers at this time. Varying package sizes need to be considered when developing standards that apply to everything. Symbols should be the first 'go to' solution, and well designed and laid out labels should be the norm. Think of your living room when guests are coming, not the closet you just threw all the crap from the living room into. Finally expanded content or even simple two sided printing of the labels helps add real estate. No matter how much you need now, it's pretty apparent that more will be needed in the future. It’s not too early to begin strategizing.
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Categories: Blog
Posted by
Dr. O on
8/3/2011 7:44 AM |
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One of my avocations when I’m not completely immersed in the wonderful world of medical device labeling is kayaking. Not the shoot the rapids type of whitewater kayaking in a boat that resembles a giant clown shoe, but sea kayaking on Lake Superior for multi day trips in long, skinny boats. We don’t always find beer (see Shelf Life post earlier) but its always interesting and exciting. Minnesota, a state that loves a good fee as much as any state, has us register our kayaks and, in exchange for our Krugerrands, give us two nice 4 x 4 labels with a big date on them to stick on our boats. This allows law enforcement to easily view the date and fine us if it’s expired. A stickers is issued for each side of the bow. I noticed the other day that the port sticker had ‘fallen off’ my boat. This sure looked like a classic adhesive failure to me but which adhesive property caused the failure?

There are 3 basic properties of pressure sensitive adhesives. The first one is tack or quick stick. It is the force of the label being pulled directly away from the substrate being labeled. Depending on what you are labeling, aggressive tack can be good or bad. Most hot melt adhesives have high initial tack while most acrylics have lower tack and adhesion that builds over time. If you are slapping a label on a damp 35F milk jug or a small diameter vial then tack is desirable. If you are labeling an expensive part or have critical positioning where the label might need to be adjusted, then that high initial tack is a bad thing. Tossing or reworking mislabeled packages is something that line personnel hate almost more than anything.

Shear is the force across the adhesive, the ability to slide on a surface. Shear is probably the least important of the three main adhesive characteristics for medical device packaging but it can be important. If the label falls off, it may have really, really low shear properties on that particular substrate. The one classic example of shear coming into play on a device package involves a cardiac product and a polyprop box that replaced a paper based set up box. During ETO cycles the paper label wrinkled due to the expansion and contraction of the polyprop box. By recommending an adhesive with lower shear the label was able to react and move a bit with the box and avoid wrinkling. It still adhered just fine.

Last but certainly not least we have peel. Peel is a crucial as well as easily measured characteristic. There are ASTM tests and various 90 degree and 180 degree peel testers, a couple of which we have in the AW packaging lab. There is also the time honored standard of picking at the corner of a label with the fingernail, lifting it, and either peeling it off cleanly, wrecking the label, or wrecking the substrate its adhered to. The ensuing comments from ‘damn that came off easy’ to ‘s**t, I just trashed the label and package’ can be discussed and evaluated.
The three of course, are related. If you think of a teeter totter, tack is the fulcrum. Peel and shear are generally opposed. A high peel strength adhesive generally has low shear strength and an adhesive with high shear generally has pretty low peel values. Either one can have high or low tack. With most device applications shear is the fat kid on the teeter totter, low on the ground and peel is the skinny kid, way up in the air. The tack fulcrum can be either high or low depending on how strongly you want that label to stay on the package initially. Tamper evident seals that go around a 90 degree angle come to mind, especially ones with the reinforced tear strip. Those need some initial tack to stick reliably in order to give the adhesion time to build to full strength for the tamper evident feature.
So what the hell happened to my kayak registration sticker? Taking the substrate out of the equation (that could be another whole post), most registration/license tab adhesives have very high tack. The sticker was on there for a few months, plenty of time for the peel properties to build to full strength. Shear is not an issue because I can’t imagine it sliding off the boat. That leaves peel. I suspect that someone, using the manual peel test I described above, heisted the thing because they were too cheap to register their own kayak. No, you conspiracy theorists out there, I didn’t peel it off to stick it on another one of my kayaks. I tried peeling another expired one off and it was extremely difficult but not impossible. The bottom line is that it could not possibly have fallen off and I guess that’s the end goal for our medical device packages as well. It can’t fall off. Peel strength criteria is set, hopefully using a pass/fail criteria of some sort, in the validation and qualification process, and the label and package are on their merry way to the end user. Now all I have to do is decide whether to spring for the six bucks for duplicate stickers or attempt to talk my way out of a fine if the warden spots me. Advice will be appreciated.
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Categories: Blog
Posted by
Dr. O on
5/31/2011 1:26 PM |
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A few years back I had a couple hernias repaired using surgical mesh, a product much like those rolls of garden mesh that keep hilly areas on your property from eroding. When asked in post op to describe my level of pain from 1 to 10, I was unable to come up with a number because at that point the anesthesia made it impossible for me to locate my own ass with either hand. However when asked if I’d like a morphine drip I knew the answer to that question immediately. Surgery went great and I was back at my desk early, wading through emails. About the 5th one I looked at was an FDA alert describing counterfeit hernia mesh that had been discovered in the US healthcare system. I got on the phone to my doc, who knows me well and kept waiting for the punch line when I described the ersatz mesh. I had to send him the email, more than a bit perturbed that a lowly label bum knew about the problem before the guy that probably stuffs several of these mesh products into patients every week. As it turned out I was fine as the mesh that was placed in me, ruining the look of one of the finest navels around if I do say so myself, was from a different manufacturer than the one the counterfeiters had targeted. It may or may not have helped, but having an additional level of security provided by a well designed tamper evident label on the package may have made the counterfeiting more difficult. In the actual alert the very first criteria that they used to describe the bad device was, “A packaging seal that does not tear open smoothly”.
Tamper evident labels are pretty simple. Notice I don’t say tamper proof, since that’s an impossible claim. Nothing is tamperproof, waterproof, or idiot proof. The goal is to make it evident and obvious that someone has attempted to breach the package to get at what’s inside. This is done by by either the label fracturing, delaminating, or leaving a gooey mess where it was on the package or the adhesive bonding with the package substrate to the point that it destroys the package material if removal is attempted. The most basic illustration of this concept is the simple price sticker on a product that can’t be removed in one piece. The epitome would be a package like a CD jewel case or any electronic device that practically requires a switchblade, hammer & chisel, and a pound or two of C4 plastic explosive to open it up. Which brings up a critical point with medical device packaging. It has to be tamper evident yet easy for the OR staff to open, use, and offer a good solid visual as to whether the package has been tampered with. The original tear tab or tear strip was developed as a result of physician complaints. The simple round or rectangular destructible label worked OK but to get it off required either a fingernail, tough when a person is wearing surgical gloves, or the use of a scalpel which then had to be tossed. The simple label is also pathetically easy to copy and fake. So……..tamper evident/indicating and simple and reliable for surgical personnel to open. That seems pretty straightforward but, like most things in our industry, it just ain’t that simple.
There are a few issues that complicate the medical device tamper evident package label and they can loosely be grouped under sterilization, package conditioning, label function, and good ‘ol ASTM 4169. Certain films commonly used for tamper evident seals do not like gamma radiation and they also do not do well at the higher accelerated aging and conditioning temps sometimes used when…gasp….validations and quals are behind schedule. Also, using the tamper evident label to hold together a SBS folding carton that’s stuffed with the double barrier package, a warranty card, and a big thick manual will almost certainly cause it to fail ASTM 4169, the shake, rattle, and roll test. So will the theory “gee, it passed ASTM 4169, lets add a ‘spike the football’ test to the protocol as well”. You think I’m exaggerating? Unfortunately only slightly. Frankly, if the seal breaks when you thump the package you should think about what’s happening inside the box, the canary in the coal mine theory. Finally, when the label is placed on the package there needs to be a clear work instruction about where it goes on the edge of the box. We often print tick marks to aid in this process. These labels typically have a reinforced peel area with small nicks to make sure the peel is reliable and secure. If it’s lined up wrong it can tear prematurely.
Actually there are a few more nuances but the ones above are plenty for a blog post like this one. Levels of security can be added like adhesive void components, holograms, color shift inks, etc., but the basic version seems to be functioning quite well and has been well received in the medical device marketplace. Its a small item that can pay big dividends if any product integrity issue do arise.
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Categories: Blog
Posted by
Dr. O on
3/11/2011 1:25 PM |
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In the last 6 months I’ve received more calls and questions on shelf life of label stock than I have in the past 5 years. They range from the request for information and data to the frenzied call that production discovered that their label stock ‘expired’ a month ago and the line will be shut down if I don’t do something. The entire concept of putting a shelf life on modern pressure sensitive label stock is a shaky and shadowy one at best, and I think its time to turn on the kitchen light and see which hole the cockroaches scurry to.
Lots of things need a shelf life; food would be a prime example. My Significant Other is a nutritional professional and I’ve had ‘perfectly good food’ snatched out of my hand and tossed in the garbage after it passed my ‘smell test’, but was past its expiration date. In the image above we illustrate a blatant disregard of any shelf life awareness at all. On a sea kayak trip on Lake Superior, the above gentleman discovered a can of what appeared to be beer that had been rolling around in Gitchee Gumee for so long that all the graphics were worn off the can. The guy in question is a Quality Professional at a Twin Cities medical device manufacturer which makes the story even better. Not knowing what kind of beer it was, how long it had been at the bottom of the lake, or if it even was beer, our hero opened the can and drank it. He said it tasted like crap but then it could have been a Lite beer. When I asked permission to use this photo, with the 50′s porn star black bar in place to protect his identity, I was required to mention that, “Surely you’ll make note that it was day 3 of very limited consumption (like only 2 beers per day). We were roughing it”. Nevertheless it is apparent that any shelf life considerations were ignored, even though this guy is the kind of fellow who would zealously monitor shelf life requirements on incoming parts and institute CAR’s, PAR’s, audits, fines, suspensions, and perhaps even a good Singapore style caning if said requirements were not met. It is also noteworthy that no ill effects, other than his normal character flaws, were noted after consumption.
But what about pressure sensitive labels, the kind we all use on terminally sterilized device packaging? Most paper label stock has a one year shelf life and most pressure sensitive films have a two year shelf life…..when stored at ambient temperature of course. But when does the countdown start on that year? When the adhesive is made? When its coated at the label stock converter? When we print and die cut it? Ship it? When its received at the device manufacturer? Clears inspection and hits the inventory shelf? That arbitrary year could be closer to two years in the case of some of the more lightly used materials. The real question is whether that date of one year, two years, has any basis in reality or can be supported by any sort of data that would indicate loss of properties after that amount of time. The answer to that question boys and girls, would be an emphatic hell no.
That one year shelf life time frame has been around for a long time, well before the widespread development and use of acrylic adhesives. My 1966 Ford Econoline van, a vehicle that always caused girlfriends parents to shudder, died a painful death at 115,000 miles. My 2003 VW Passat was sold to a friend when it had 200,000 miles on it and now has closer to 300m. I believe the reason for that was an improvement in technology. Pressure sensitive label adhesives have similarly improved over the years as well.
Advanced Web, with the help of one of our label stock vendors and at the request of a device manufacturer, did some studies on adhesion over time. We took some current paper label stock, laser material to be exact, with an acrylic emulsion adhesive and tested and compared it against 4 year old retains of the same material. We did peel, shear, and tack on 4 common substrates including PETG, Tyvek, SBS cartons, and a stainless steel control. There was statistically no difference in the numbers between the two materials. When I discussed this fact with the Technical Director at our vendor, he was not surprised at all. He even sent me a letter, on company letterhead, stating that, “In reality, nothing dramatic should change with a PS labelstock construction after one year. The acrylic adhesive is chemically stable and will not oxidize or loose tack. The silicone release liner should stay near the same level as well. In summary, the PS labelstock construction should retain its functional performance after one year. Likewise, after the label is applied,the adhesive does not degrade or lose tack over time…..” Many device companies have 5,7, and 10 year real time shelf life info on their products and I have not heard of one PS label failure in all of that real time testing.
So, does one year shelf life for PS label materials make any sense at all based on the evidence. Nope. Will this evidence and the informed opinions of technical folks involved in the industry make any dent in this beloved one/two year time frame? Nope. Is a shelf life date even necessary for most modern label stock, given reasonable inventory control, production cycles, and FIFO? Nope. So please forgive me if you hear a sigh, a cleansing breath, when you call me with your underwear on fire about 13 month old label stock, 13 months from some magical, arbitrary, ephemeral start date. I’ll probably calmly ask you what substrates your labels are being used on, send you that letter I received from our vendor, bust our production’s hind ends to get you some ‘fresh’ label stock, and maybe even attach this blog post to my delivery confirmation email. Given regulatory paranoia, I do not see any light at the end of this tunnel however, so we need to be content to wallow in and perhaps even enjoy non-value added time sucking activity. On the label shelf life issue, the mouse traps are carefully set as the elephants are stampeding through the front door.
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Categories: Blog
Posted by
Dr. O on
2/16/2011 1:23 PM |
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Foreign material or FM can be loosely defined as something that’s not supposed to be present or part of the base material that’s being produced. The fact is that foreign material is always present in everything that is produced, no matter how much we wish that it wasn’t or how strictly we word our engineering drawings. It will be there so the key issue, twin issues actually, are how much is allowable and what exactly is the composition of the FM.
In the photo above its pretty clear that the allowable ppm of foreign material as well as the maximum size of the particulate has been exceeded. That’s what can happen when a couple of guys are tinkering with ink pump hoses that are under pressure. We know what the ‘foreign material’ is however. It is solvent safe water based black ink, approved for indirect food contact under FDA regs. Is it a health hazard? Not according to the MSDS sheet. Does it pose some disturbing cosmetic issues for those who might encounter these two yahoos? I would say the answer there is yes. So we have a known substance that is relatively inert, but just doesn’t look that great. Coincidentally, we had the same issue with some laser face stock from one of our suppliers. It opened up a large can of worms in regard to what it actually was, how much was allowable, and the perception of how it looked on a package.
In November of 2010 we began to see large (some half the size of a fingernail) spots on one of the paper laser sheets that’s qualified and validated at a number of our device customers for labeling terminally sterilized medical device packages. The paper industry has not been exempt from the go faster/make it cheaper pressures of the marketplace and we suspect that increased machine speed and less inspection might be the culprit. We discovered that the foreign material was calcium carbonate (which would actually make it parent material by definition) used in the paper making process. It’s a naturally occurring mineral and is commonly used, among other things, as a calcium supplement in diets and a key ingredient in antacids. Basically, people can eat it. Unfortunately, these specks had a rust colored hue, a color that looked very similar to dried blood. Our supplier had no interest in attempting to correct the issue since medical device usage is the proverbial flea on the elephants butt of total laser paper usage. We were sent a letter informing us that our vendor would no longer support our medical device application in early May of 2010. We informed our device customers and the gnashing of teeth and over thinking of the issue began in earnest.
The perfect solution would be not to have any at all. Unfortunately, a line on a drawing or print that says “There shall be no foreign material present on the printed side or adhesive side of the label” does not make the FM go away or even scares it a little bit. For example, neither you nor I want insect and rodent parts or mouse dung in our bread. Yet the FDA, those same guys that regulate our industry, have an allowable ppm for those very substances in flour. I worked in a bakery during part of college and one of my jobs before the inspectors came through was to thoroughly clean the dough mixer and vacuum up all flour bug tracks underneath it. At times it looked like Grand Central Station under there. So the real question becomes how much FM would be allowable?

Enter the venerable TAPPI chart. The most widely accepted particluate standards were developed in 2004 by Tyvek and film converters. Some of you may remember the 1073B Tyvek recall in 2001, when black FM from deteriorated brushes in the Tyvek production line in Richmond broke off and became embedded in the sheet. Many device manufacturers had standards before that and an ASTM group headed by some J&J folks attempted to come up with a standard but it never came to fruition. The current most commonly accepted working standard combines both embedded and loose FM with a maximum allowable size and maximum particulate count for smaller sizes. It addresses both parent material, components of the actual structure itself, whether it be Tyvek, film, or paper, and foreign material that is not part of the manufacturing process. If you sent him a nice email, Mr. Curtis Larsen of Spartan Design Group might send you a copy of some work that he did on FM on various substrates. Just don’t mention this years MSU basketball team. The other key part of FM evaluation is that the parts need to be examined at 18″ with the unaided human eye for two seconds. Poring over a label or lid for 20 seconds with a 6x magnifying loop is definitely not the accepted procedure.
The FM in the laser sheet face stock issue is still unresolved. Qualification and validation of the alternative cleaner, more bright white materials is crawling along at glacial speed at exactly 100% of our customers. However the main thing that dealing with the medical device industry has taught me is patience. One of my MedDev buddies, an engineer at a large device manufacturer, counseled me, “Olson, you gotta be patient. If the FDA regulated the auto industry your car would not have an electronic ignition and it wouldn’t even have points and a condenser. You’d have a magneto because magnetos are historically proven to be reliable”. It is the same with implementing the commonly accepted FM standards. 2004 to now is a mere blink in both geological and medical device time. I would encourage medical device companies to at least lurch forward toward adopting a practical and workable FM standard
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Categories: Blog
Posted by
Dr. O on
3/24/2010 11:55 AM |
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Healthpack was the usual rousing success with a sellout crowd at the Gunther Hotel and along San Antonio’s Riverwalk. There were some casualties in the rough and tumble world of terminally sterilized medical device packaging but for the most part things were under control. I think the gentleman in the photo was an innocent bystander in a river front brawl between the ISTA and ASTM 4169 gangs over the package distribution standards turf. Another rumor was that the E labeling posse and the printed leaflets/IFU boyz came to blows again, but it’s unclear at this time. It was a good conference though, and many of the topics were germane to the issues of the day and a number of new ideas were explored.

When good HealthPacks go bad...
One of the more interesting ideas was proposed by Nicholas Berendt of the Sealed Air Corp., a converter of sterile barrier packaging. The theory was if the converter, (eg the company that takes raw material and prints, diecuts, laminates, folds, spindles, and mutilates it into pouches, lids, labels, IFU’s, etc.), could to a series of tests up front and provide data, it could seriously reduce package engineering time validating new packaging films as well as increase speed to market. I have thought for a number of years that the same thing could be easily done with new label stock. The testing is not nearly as rigorous as what would be needed for a barrier film and pre qualification might make it easier to qualify and validate new label material. As I mentioned in my Healthpack presentation, labeling is usually a very small part of the total package as far as cost and time and effort thats devoted to it. Because of this, available engineering time to test new materials, including label stocks, is generally limited and not in the number one spot on the package engineering agenda. Due to this ‘fact of packaging life’, the older, larger, more established companies are driving the ’89 Chrysler Cordoba of label stocks while newer companies, who have to evaluate all their new packaging materials anyway, are zipping along in the ’09 VW Passat, 1.8L Audi Turbo label stocks. While it’s true that the established firms have the fine Corinthian leather, they don’t have all the new innovations and added features of the newer models. These would include brighter, whiter, more opaque face stocks and tackfied emulsion adhesives that have decent repositionable characteristics in final pack yet superior ultimate bond to tough substrates like tyvek. Plus the new materials are a solid 25% less costly than the older materials. That should make the purchasing and sourcing peoples ears perk up but again, as a percentage of the total expense of the product the label part is still puny; we’re talking about a deck chair on the Titanic here.

Distinguished gents of HealthPack
The question then, is if we performed a series of ASTM and other tests on new label stock that addressed the twin FDA regulatory concerns in CFR 21, Part 820, the Quality System Regulations, of adhesion and legibility, would that be of value to device manufacturers and in particular packaging engineers? I realize that package size and weight are crucial to package testing and that special conditions need to be considered for various configurations, but I can’t help but think that if you need to get from Minneapolis to Milwaukee, that starting out in Madison would be a lot quicker, less costly, and less painless than starting out in Minneapolis. Please weigh in on the attached poll and let me know how you feel your company, particularly your Reg Affairs folks, would react to this concept. I will anxiously await your feedback.
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Categories: Blog
Posted by
Dr. O on
1/26/2010 11:53 AM |
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Almost 174 years to the day, after Jim Bowie, Davy Crockett, William Travis, and a couple hundred others were killed defending the Alamo, the upteenth annual Healthpack Conference is coming to within 4 blocks of the historic mission in San Antonio, TX. In a weak moment I was approached by the instigators (agitators?) of the event, Messers Spitzley and Larsen, and agreed to craft a presentation which they entitled, “How to test your package system labels for materials compatability and adhesion over time“.
It’s a critical topic but what we discovered in a survey that was taken by the IOPP Medical Device Technical Committee’s Labeling Task Group, no one does it exactly the same. The FDA gives us a broad and general edict in the Quality System Reguilations, CFR 21, Part 820, Subpart K. “Label Integrity. Labels shall be printed and applied so as to remain legible and affixed during the customary conditions of processing, storage, handling, distribution, and where appropriate, use”. In a nutshell, the label needs to stick to the packaging component substrate and stand up to the abuse of sterilization, shipping, handling, and storage until it gets thrown away. It also needs to remain readable after this journey from manufacturing final pack to the landfill. How to test for these qualities and predict how well the labeling on a terminally sterlized device package will survive is the topic I’ll try to address.
Rather than standing up there and presenting what I think people are interested in, I thought I’d use this forum to see what people that work with device labeling day in and day out actually want to hear. Take a look at the survey that we took last fall (attached below), which had ten basic questions. Part of the presentation will be based up on those responses, which come from a broad spectrum of device manufacturers, but I know there are additional issues, test methods, and techniques that should be addressed. One of the things we are working on in the Labeling Task Group is some sort of protocol or guidance that can be used to help qualify and validate pressure sensitive labeling of terminally sterilized device packaging. Any feedback via email or blog comment section would be helpful to the group.
Labeling Task Group 09
I know budgets are tight but Healthpack is a pretty useful conference for those of us in medical device packaging. I can’t pretend that all the presentations have been scintillating over the years, but there are a heck of a lot more useful and interesting presentations at this event than at most others I’ve attended. There is nothing wrong with San Antonio, the historic Gunther Hotel, or Riverwalk either, for that matter. Please take a couple minutes to give me some feedback on the topic of pressure sensitive labeling. If you don’t who knows what you might wind up with in early March…..

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Categories: Blog
Posted by
Dr. O on
1/17/2010 1:21 PM |
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Due to a number of reasons, the main one being my chronic TCS (Time Compression Syndrome, a malady that consistently has victims attempting to shove ten pounds of fertilizer into a five pound bag), this blog has not appeared since about March of last year. That flaw will be remedied this year with a regular monthly post, maybe more if there is breaking news, which I plan on posting the first week of each month. There is plenty to write about in the field of terminally sterilized medical device packaging and labeling these days and I hope to hit a few germane topics as we progress through 2011.
One of the things that we worked on last year was an expansion of the small one page handout that many of you picked up at either Healthpack or one of the MDM shows. Its a neat little retro-looking spiral bound booklet with a bunch of good stuff in it, ranging from design tips to a bunch of label related websites. If you would like one, either shoot me an email or give me a call at 612.706.9554.
MDM West is coming up in a couple weeks and MDRG, the Medical Device Resource Group, will be hosting a reception at the Hilton Anaheim on February 8th. Healthpack 2011 is right around the corner as well, rapidly approaching in early March in the Queen City of Cincinnati. More to follow on both items. 2011 is out of the blocks rapidly and there is a lot of labeling stuff in the hopper. Blog post 2 for 2011 will be out in two weeks.
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Categories: Blog
Posted by
Dr. O on
11/10/2009 11:44 AM |
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Way back in the distant past, it was Underwriters Laboratories that helped turn Web Graphics into Web Label and, eventually, Advanced Web. We did manuals and other printed material for Litton Microwave, back in the day when a company could actually produce a microwave in the US. Since most microwaves plug into the wall, Litton management felt that UL approval would be a positive thing. They had trouble with their label vendor and asked us if we were interested in producing UL labels for them. We told ‘em heck no. They asked again and we firmly said no again but eventually came around and started printing labels. So much for forward thinking, proactive business strategy in the mid ’70′s. It’s worked out OK over the years however. And a couple of Litton execs made their way into the medical device field, Bill George and Dale Wahlstrom.
A number of our medical customers have devices that plug into the wall. Generators and controllers for arthroscopic surgery, and the console/controller for a blood pump are two examples. Most of those products are UL certified but the question of what type of labels and marking systems are needed can be a bit murky at times.
Both our raw material suppliers as well as Advanced Web can get UL recognition. Basically, they send their blank label stock and a pile of money to UL. We send our printed, laminated, and diecut label stock and a pile of money to UL. They then perform a series of tests, many from a standard called UL 969 (available for purchase) which qualifies our label ‘system’ for use indoor, outdoor or both. Raw material is certified under UL Marking and Labeling Systems Material – Component program PGGU2. Our labeling system is certified under Component Marking and Labeling Systems PGDQ2. In order for us to recommend the correct label system, we need to know the surface it adheres to and the temperature range of the product. That’s it. We have different colors and finishes but that’s basically all the info that’s needed to qualify a label. One thing that tends to throw people off their game is that almost all of these products are tested to be ‘removable intact’. What this means is that the label can be pulled off the part in one piece without fracturing. Many of us think of a ‘UL label’ as the paper label that’s as fragile as a K Mart price sticker with the UL logo on it. That is not what this program is about. When the UL inspector visits your plant, and he visits ours frequently, he will check the carton label and a core or package label on your label inventory. He then looks it up in the Component Directory, formerly a large, thick, yellow two volume book, but now just a number of bytes floating around in cyberspace. Not surprisingly, that’s available for purchase as well. If the label designation on the carton and core are in there, and the surface the label adheres to and the temperature range match, you are golden. If not, bad things begin to happen.
I’m afraid I don’t have much insight on who does or doesn’t need the PGDQ2 or PGGU2 system. I’ve surfed the UL website and spoken to 4 UL employees and its still a bit puzzling to me. We recently had a project where the end user realized that a UL labeling system was needed. Unfortunately it was after the labels had been produced and the prototypes built and put into testing. We had produced the material on UL material (PGGU2) but not using one of our Component Marking and Labeling Systems, (PGDQ2). The verdict is out on whether or not that will do the trick but we should hear shortly.
In a nutshell, if you need a UL system, check with your UL project manager, either at UL, or internally if you’re a gigantic device manufacturer, to see which designation will be needed. I was told by UL that if you guess wrong, only choose the material designation, and they discover the label is printed, that they will test the labels (remember the pile of money?) to make sure it meets standards. The safe route is to choose PGDQ2, identify the material the substrate is made of, determine the operating temperature range, decide on the finish or color of the label, and test a couple samples. Another riff on the UL story is PGJI2, the repackage program. In a nutshell, we diecut blank labels that can be demand printed with thermal transfer printers using qualified UL tested (another pile of $$) ribbons. Keep in mind the removable intact requirement on all of these systems. UL does not say that just because the labels stick nicely to a smooth ABS surface that they will stick nicely to a textured ABS surface. They won’t! Identify the device, identify the UL system, and test. It’s the only reliable way to get what functions well and meets the UL requirements.
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