2024

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WILMINGTON, DE, October 1, 2024 – DuPont (NYSE: DD) announced the winners of its global awards program, the Tyvek® Sustainable Healthcare Packaging Awards, during the virtual Medical Packaging Conference (MPC) hosted by DuPont. This annual awards program recognizes leaders across the healthcare industry who are embracing and driving sustainability throughout the packaging lifecycle. 

The three winners, who utilize healthcare packaging made with DuPont™ Tyvek® material and whose efforts show a significant focus on sustainability, are: Shawpak in Operational Efficiencies, PAXXUS in Packaging (Re)design and Flexform Incorporated in Sustainability in-use.

Operational efficiencies: Shawpak 

 Shawpak provides a range of packaging machinery dedicated to the medical device industry. As a revolutionary machine, the rotary drum concept offers a unique thermoforming solution to packaging needs. The machine is designed to accept multiple tool and pack sizes, and all machines are designed to form both rigid and flexible blisters as standard. This allows an effective solution for Tyvek® material to be paired with any rigid or flexible material to form and seal the package. 

Shawpak takes an innovate approach when designing machines with sustainability In mind, the Shawpak takes up significantly less clean room space (<2 sq/mtr) than a traditional thermoformer (>1m x 4m-9m). It has also been designed with no waste trim on flexible packs, the unique pneumatic gripper system eliminates the need for waste disposal whilst using Tyvek® and flexible film. 

Many other benefits with the rotary thermoformer include product control, the package can be designed to closely suit the product size meaning the package can be made smaller reducing excessive waste, shipping and sterilization costs. The material in system is less than 1m on form and top web, reducing waste on change overs and provides high levels of control on material tracking. When considering energy consumption, the Shawpak rotary thermoformer only requires single phase power and 2-3 cfm air consumption. 

‘’ We are absolutely thrilled to receive this recognition for the innovative approach Shawpak takes when designing machines with sustainability in mind. We take great pride in how we approach new machine development ensuring that we help medical device manufacturers to reduce waste and cost without compromising end user requirements, safety and pack quality. To get this award from a healthcare giant in DuPont Tyvek® Healthcare Packaging is something we at Shawpak are extremely proud of.’’ Tony Crofts, Sales Director of Shawpak.

“The advancements in sustainability showcased in the winning programs for the 2024 DuPont™ Tyvek® Sustainable Healthcare Packaging Awards are a testament to how these companies are dedicated to making meaningful environmental strides within the healthcare industry,” said Kelly Reichert, global business director, DuPont™ Tyvek® & Typar® Roll Goods. “Our DuPont team is dedicated to working alongside our customers and others in the healthcare and healthcare packaging industry to foster continuous collaboration and help them advance sustainability and enable product and patient safety. We join these award winners in viewing advancements in sustainability as an important extension of why we do what we do.” 

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©2024 DuPont. All rights reserved. DuPont™,

the DuPont Oval Logo, and Tyvek® are owned

by affiliates of DuPont de Nemours, Inc.

The Challenge

BMP Medical is a world leading manufacturer and supplier of Tissue Grinders and understands the importance of seeking more efficient and cost-effective packaging solution for their products. Their current packaging method, utilizing pre-made pouches that are 72sq/in size, was inefficient in terms of material usage and labour requirements.

The Solution

BMP Medical first met Shawpak at MD&M West Pack 2024 whilst seeking a small footprint thermoforming packaging machine. Shawpak’s compact 32-20 rotary thermoforming machine proved to be the ideal fit for BMP’s needs, offering the flexibility and efficiency required for their production process.

Shawpak's application engineers worked closely with the engineers at BMP Medical to design a unique thermoformed package to best suit the product whilst minimizing material usage. This also means more packs per case reducing the cost in sterilisation and shipping. This collaborative approach resulted in a package that was significantly smaller, 28sq/in, than the previous 72sq/in pre-made pouches, reducing material consumption by over 60%.

The Results

The implementation of Shawpak’s medical thermoforming packaging solution has provided substantial benefits for BMP Medical:

• Reduced Material Consumption: The smaller thermoformed package leads to a significant reduction in material usage, resulting in cost savings and a smaller environmental footprint.

• Increased Efficiency: The new packaging process will streamline operations and reduce staff from 4 per week to 2 over 1.5 shifts providing a significant cost savings. This will allow BMP Medical to increase production without additional labour.

• Improved Cost-Effectiveness: The combined reduction in material and labour costs significantly improves BMP Medical's overall cost-efficiency.

Customer Testimonial

‘’A lot of the processes at BMP are automated with heavy investment in recent years in robotic cells. The packaging of our Tissue Grinder product range has always been an area where we knew we could improve the efficiency by automating the packaging process. Over the years we have looked at various thermoform machines, but all were very large in footprint which prevented us from making the change. 

Whilst visiting the 2024 MD&M trade show in Anaheim CA we came across Shawpak and saw firsthand their unique Rotary Thermoform Machine; it was ideal for what we needed.

Working with the Shawpak application engineers we quickly made prototype packages which looked great and gave us the confidence to move ahead with the machine purchase – 4 months later the machine and tool were complete and heading to our facility in Massachusetts.”

Michael T. Faulkner, Chief Executive Officer & President

BMP Medical

Derby, UK (September 2024) – Manufacturer of medical packaging equipment Shawpak announces the hiring of  Will Ellis as Finance Director. 

We are pleased to announce that Will Ellis has joined Shawpak as our new Finance Director! Will brings a wealth of experience improving finance processes, in capital equipment and manufacturing. 

With his previous role as European Finance Director for 18 years at a global packaging machinery company and overall experience of 33 years in finance, Will is extremely excited to streamline and support Shawpak’s growth and vision. 

UK based medical device contract packaging company Riverside Medical Packaging Ltd  announce the demerger of their business unit Shawpak. 

Due to the growth achieved by Shawpak since its inception in 2014, the directors of Riverside Medical Packaging Ltd have decided to split the operations into two separate legal trading entities which will result in the trading activities of Shawpak transferring to Shawpak Limited. The new Shawpak company will have the same ownership and Directors as Riverside Medical Packaging Ltd. 

The transfer of trade is expected to occur on 1st February 2024. Given that Shawpak has always operated as a separate division, there will be no change to its’ day-to-day activities. Post demerger Shawpak Ltd will continue the strong collaboration with Riverside Medical Packaging on providing technical and innovation support ensuring the highest levels of service to their customers. 

Riverside Medical Packaging Ltd is a leading medical device contract packaging company and medical pouch manufacturer based in Derby UK, established in 1979. 

Shawpak Limited is a manufacturer of a range of medical device packaging machinery ranging from its unique rotary thermoform machine to 3 side seal pouch making and rigid tray making machinery. Since investment in distribution and manufacturing Shawpak has established an install base in over 25 countries and a subsidiary in the USA (Shawpak USA Inc) whilst supplying equipment to some of the largest global multi-national medical device manufacturers.

From the initial concept of Shawpak the aim was to invest into and grow a medical device packaging machinery business to a point where we would establish it as a standalone business states CEO David Shaw. It is with great pride and excitement that we embark on the next phase of both Riverside Medical Packaging Ltd and Shawpak Ltd as we continue to grow and establish ourselves as a leading supplier to the medical device industry across the globe.

Shawpak has achieved certification by UL Solutions, as an authorised UL approved panel manufacturer, to UL standards 508A.

UL 508A is the standard for, ‘Safety For Industrial Control Equipment’, and covers industrial control and related devices rated to 1500 volts or less used for starting, stopping, regulating, controlling, or protecting electric motors.

Panels can now be designed, manufactured, and built in-house, compliant to UL 508A standards and shipped to the United States. This was required for establishing and maintaining standards related to safety protocols and compliance.

Chris Scopes, Engineer Director, ‘’Gaining UL Certification allows Shawpak the ability to maintain full control of the entire electrical design phase of a machine’’.

As UL is the leading nationally recognised testing authority in the US, it was significantly important for Shawpak to achieve the accreditation. Due to increasing orders from the United States for Shawpak’s range of packaging machinery, it was critical that we developed our processes to ensure compliancy to UL standards on panel manufacturing. 

Shawpak’s electrical team underwent rigorous training and appointed Darryl Orridge, Electrical Design Engineer, as UL MTR (Manufacturers Technical Representative). As well as training, Darryl carried out an examination to qualify for the certification. Soon after, documentation and schematics were submitted for the first IPI (Initial Product Inspection), to undergo testing against standards developed by UL. For the next three years, Shawpak has accreditation to manufacture panels and will be subject to quarterly inspections by UL Field Services to ensure compliance consistency is maintained.

This process has given standardisation to procedures and allows Shawpak the capacity to apply UL principles and standards to panels, which are fitted in the Shawpak Range of Packaging Machinery.

Along with UL certification Shawpak recently completed the implementation of Allen-Bradley as its standard control system on all new machines. Standardisation of our technical processes is critical for our continued growth and increase of machinery orders.

References https://www.ul.com/sites/g/files/qbfpbp251/files/2019-05/Industrial-Control-Equipment_us.pdf 

This year will be Shawpak’s first interpack and we are excited to be in the Processes & Machinery Hall (15) for the packaging of Medical, Pharmaceuticals and Cosmetics with our range of medical packaging machinery.

It has been a busy few years preparing for the show as we have switched our controls systems over to Allen-Bradley. Interpack will be the first time we launch our Shawpak Pouch & Shawpak Rigid Blister Machines with the new Allen-Bradley Controls. Chris Scopes, Engineering Director of Shawpak, directly lead the development starting with the Shawpak Rotary Thermoform Machines in the summer of 2021.

Fast forward to 2023, it has taken 18 months to completely implement the change on all Shawpak machinery platforms. Making the move to Allen Bradley not only gave several technology improvements it also better served our customer requirements with a large part of customers being based in Europe and North America. Implementing the new technology allowed us the opportunity to standardise software which was critical for our continued growth and increase in machinery orders.

Shawpak are showcasing four medical packaging machines at the show. This includes the Shawpak Rotary Thermoform Machines, Shawpak Pouch Machine and the newly launched Shawpak Rigid Blister Machine. 

Our latest development has been the Rigid Blister Machine, our customers have recently seen challenges due to supply chain issues relating to the supply of pre-made packages which gave shawpak the opportunity to develop machinery that allows our customers to vertically integrate their packaging needs and bring the packaging manufacturing in-house. The Shawpak RBM offers a solution to customers who are experiencing long lead times for pre-made packages and allows them to convert their own packaging from roll stock and on demand to their production needs at the point of requirement, the machine will be in action at interpack in Hall 15 Stand D57. 

Ali Amin (20) was shortlisted for National Apprentice of the Year after winning the East Midlands regionals  in October. Alan Wade (Operations Director) and Ali attended the National Apprenticeship Awards on 30th November, where Ali won the award for Advanced Apprentice of the Year.

Joining shawpak in 2019, Ali started his apprenticeship working as  Mechanical Build Engineer which later progressed to Electrical Build Engineer and then Technical & Test Engineer. In 2022 Ali started his higher level 6 degree-apprenticeship with University of Nottingham as Electro-Mechanical (Mechatronics) Engineer, which will continue for  5 years. 

''I'm very thankful for the support from everyone at Shawpak and University of Nottingham which helped me achieve this award. I look forward to continuing to work at Shawpak and progressing my career further. During my apprenticeship I worked in the build, electrical and test departments,  as I progress with my higher degree I'll be working in the design and software departments whilst achieving my bachelors in Electro-Mechanical Engineering.''

Ali has also joined the East Midlands Apprenticeship Ambassador Network (EMAAN) and works closely with Landau Forte College , University of Nottingham & Derby College.

Shawpak are proud to work with local colleges to offer apprenticeship schemes, to welcome new apprentices and allow new opportunities for existing employees. Investing in workforce is important to both our employees and Shawpak. 

July 12-14th 2022 we hosted Shawmed, the UK's largest in-house medical device packaging exhibition showcasing the latest manufacturing technology and products for the healthcare sector.

Over the three days we were joined by co-exhibitors AMACO GmbH, SP Automation & Robotics and STERIMED Infection Control to provide a turn key solution for medical device packaging. 

We invited guests to explore the revolutionary shawpak portfolio of medical packaging machines, medical materials and ancillary applications.

It was a very busy and exciting three days, meeting new prospects, existing clients and catching up with our industry suppliers. Our goal was to provide a solution for medical device packaging and give inspiration by showcasing the newest technology on the market.

Click here to watch Shawmed 22 

San Diego, CA (April 2022) – Manufacturer of medical packaging equipment Shawpak USA Inc announces the hiring of new recruit.

Frank Szappanos has joined as Field Service Engineer for North America. 

Frank brings with him over 6 years experience working within the packaging machinery industry working on a range of HFFS, Manual and Automatic Tray Sealers and Flow Wrapping machines and also has extensive thermoforming experience. 

We're thrilled to introduce the newest and watch our US team grow.

 UK based medical packaging machinery company Shawpak announce the launch of its new 4 Side Seal (4SS) pouch machine delivering a highly flexible and innotive solution for packaging flat medical products. The addition of the Shawpak 4SS machine allows us to offer a complete portfolio of packaging solutions to our customers in the medical and pharma arena. 

This is another Shawpak packaging solution that will transform the industry norm of ‘how it has always been done’ – Tony Crofts Sales Director Shawpak

Developed, designed and created by shawpak, this unique packaging machine is one of the latest developments within the shawpak portfolio. 

The Shawpak 4SS is designed to pack flat products to a maximum thickness of 5mm in packs up to 600mm x 340mm and can produce outputs in excess of 4000 packs per hour. The machine can also be utilised to make 3 side seal open pouches allowing medical device customers to make their own pre-made packs to hand fill and seal. Incorporating the latest technologies and innovative functionality helps to ensure high efficiencies and low maintenance. Other beneficial features include a compact bespoke design which allows a small footprint, saving valuable floor space, and utilises modular assemblies for quick changeovers and improved accessibility. 

Understanding customer user requirements and limitations in the current standard market solutions was key in the development of Shawpak’s 4SS machine. Incorporating many features to enable ease of use and low cost tooling.

Videos of the 4SS machine are available on Shawpak’s YouTube channel and on request from sales@shawpak.co.uk 

Shawpak are proud to present a new multi-lane rotary thermoform machine. 

The multi lane machine can produce up to 5,000 packs per hour with our revolutionary rotary drum. In this application we can supply a fully integrated solution which includes the proprietary thermoform machine, inline thermal transfer printer, vision inspection, robot loading of the product and a reject system all within a 2 mtr/sq footprint. 

Being so compact with a small footprint, it is easy to move and free up space in high cost production environments. The unique design and tooling of shawpak thermoforming packaging machines is what gives it the edge.

 Riverside Medical Packaging Company Ltd were given the opportunity and challenge of producing over 6 million face shields between August and December 2020 to meet small and large customer orders. 

Ramping up the production of face shields meant Riverside Medical Packaging Ltd needed to design and build 2 brand new Face Shield Manufacturing Machines and give commitment to the meeting the demand of the largest customers.

Shawpak is the engineering division of Riverside Medical Packaging Ltd and led the design and build of the Face Shield Machines. With the dedication of the design, manufacturing and engineering teams the two machines were completed and in production within just 6 weeks. This is a phenomenal achievement and one that has shown the grit and determination of the whole team when faced with such a huge challenge.

In such extremely challenging times the design team have had agility, flexibility and speed to create such unique and important machines.

“Starting from a blank sheet of paper, everyone worked as a team to pick up the challenge to design and build two new machines and complete the job in record time – just six weeks. The result has been extremely impressive and one that we are all proud of – the machines are running reliably 24 hours a day, with higher production rates than forecast, whilst producing high quality face shields to meet the demand of both small and large orders in the fight against Covid19.” - Ivor Rowe the technical manager at Shawpak.

After the face shield machines were designed these were then manufactured in house at Shawpak’s extensive machine shop. The recent investment of over £2m in the facility and machining centres including the five-axis Chiron milling machine and two high speed flat-bed router cutters meant our experienced workshop engineers could meet such complex designs and the high volume of parts required in a short space of time.

David Shaw, CEO of Riverside Medical Packaging “Riverside Medical Packaging Ltd has always invested in the engineering side of the business and understood the importance of this to support our customers, it has helped us grow from a small medical pouch making business in the 1980’s to the business we are today supplying millions of pouches to the medical industry along with high quality contract packing, medical device manufacture and more recently in the design and development of the revolutionary shawpak medical thermoform packaging machine range.

When tasked with supplying millions of face shields with a very short lead time I felt confident that the team at Riverside Medical Packaging Ltd and shawpak would succeed in sourcing the raw materials to make the shields as well as developing the equipment to manufacture them. Producing the machines and sourcing all materials in order to meet the high demand in 6 weeks is veryimpressive”-

The capacity of both shield machines means Riverside are able to produce 1 ½ million shields per month. Thousands of shields have already been made and sent out to various customers.

A small footprint thermoforming machine which can be easily integrated with robot loading is an ideal single piece flow solution for medical device manufacturers. Taking up an average of 70% less floor space than conventional thermoforming equipment the shawpak machine is an easy fit at the end of assembly and production lines allowing you to directly package products without double handling or storage reducing product movement around the facility and decreasing WIP/Stock. The ability to directly pack the product with the Single Piece Flow process production efficiencies are gained by no tool changes and reduced double handling on medical devices. 

Robotically loading the machine with high repeat accuracy and high speed is advantageous in the medical sector as many robots are available for use in clean rooms. Having a reduced loading area allows the shawpak machine to keep pace with the assembly lines whilst making the automated loading simple with most applications utilising a 4 axis SCARA robot.

The innovative shawpak machine brings not only an increase in efficiency but also future proofs your production plans. The machine is designed to accept multiple tool and pack sizes and all machines are designed to form both Rigid and Flexible Blisters as standard. The shawpak thermoforming machine is very versatile and made to each customers bespoke application. 

On all flexible blister packs there’s zero trim or waste, and on all rigid diecut packs there is very minimal waste reducing the overall material used. The unique design allows materials to be run at almost any web width up to the maximum machine size, giving you the freedom to design the packaging around your specific product. The pack dictates the tooling size not vice versa.

In summary the shawpak machine changes the way production lines are designed in cleanrooms, directly packaging products from the assembly lines through the single piece flow process is a game changer for the medical device industry and shawpak are at the leading edge in supporting businesses to achieve this.