When it comes to healthcare packaging, the heat-sealed lid and rigid tray sterile barrier system is a go-to solution. This combo ensures the protection and preservation of medical and pharmaceutical products until they’re ready for use. However, designing the right heat-sealed lid for your custom rigid tray is essential for ensuring the sterility of your healthcare products.

Material Matters

Selecting the right high-quality material for your custom die-cut lid is a significant choice during the design and purchase processes. It affects how well your product works, how safe it is, and its shelf life and storage needs. When choosing a material, you have to consider what your product needs, how people will use it, and whether it meets healthcare regulations and testing standards. In addition, key considerations often include user experience and aseptic presentation.

The material you pick has a crucial role in protecting your product during sterilization, transportation in healthcare settings, and storage. If your product is going to sit on shelves or pallets for a long time, the material choice becomes even more important, as some materials are better suited for storage needs.

For processes like gas sterilization, materials like paper and coated Tyvek, which allow air to pass through, are often chosen due to important factors of permeability and barometric pressure. 

Some lids use heat sealing film or instead, use a mix of materials, such as paper, poly, and foil, to become tamper evident and create a barrier against things like moisture and oxygen to protect the enclosed items from the outside environment over time.

When selecting the right materials for your heat-sealed lid, you should also consider legacy test data and regulatory approval, to ensure that your high-quality product follows industry standards and regulations.

Packaging Equipment Automation

When delving into the realm of packaging equipment automation for your sealable lid, it’s crucial not only to focus on the material selection but also to take a close look at the sealing process. The annual production volume and type of sealer employed for heat sealing can significantly impact the efficiency and viability of your packaging solution.

The choice of packaging automation is intricately tied to the scale of your production. High-speed form-fill-seal machines come into their own when dealing with larger annual production volumes. These machines deftly handle web-based lids, swiftly and efficiently creating a seamless packaging process. They are a go-to solution for industries with high output demands, streamlining the packaging workflow with precision.

However, for lower production volumes or single-piece flow, manual shuttle tray sealing machines emerge as a more cost-effective and practical choice. These machines employ individualized cut sheets and allow for a hands-on approach, facilitating manual inspection — a crucial aspect, particularly in medical packaging. The ability to visually assess each package ensures that quality control remains paramount, especially when dealing with sensitive medical products where precision and accuracy are non-negotiable.


When it comes to designing lids, one of the critical considerations is the peel-ability factor — a feature that can make or break the user experience and functionality of the packaging. Lid designs often encompass three main categories: peelable, resealable, or non-peelable, each catering to specific application needs.

Peelable lids, in particular, add a layer of convenience by allowing users to easily peel off the lid, exposing the contents beneath. An easy peel lid might be desirable for some healthcare applications where the enclosed healthcare tools must be accessed quickly or without the need for special tools to open. This feature is typically achieved through the incorporation of a laminate layer or a specially coated adhesive, such as coated Tyvek or any of our Techni-Coat products. The success of this peeling functionality hinges on the seamless compatibility of the chosen materials with both the tray material and the equipment parameters used in the packaging process.

The laminate layer or coated adhesive must strike a delicate balance, ensuring that it adheres securely during the packaging process but readily peels away without any fuss when it’s time for the end user to access the product. This is especially crucial in industries like healthcare, where quick and contamination-free access to medical supplies or devices is paramount.

Sizing Strategies

When it comes to figuring out the right sizes for packaging, it’s important to tailor your approach based on the type of machine you’re working with and their specifications for web width and tool design that the form-fill machine can accommodate. When selecting the right web-based roll for your machine, consider the roll’s width, core size, maximum diameter, and the type of coating or peel layer that will be used. 

Now, when you’re dealing with shuttle tray sealing machines, it’s a bit different. These machines often opt for oversized lids with “overhang,” a clever choice that allows the lid to be more easily separated from the tray and located in the seal nesting tray of the sealer. How much to oversize the lid so it does overhang the tray is determined by stacking up the tolerances. For most thermoforming operations, the “cut registration” or the amount the tray’s form will vary in respect to the outside cut will be +/- 0.047”, with sometimes smaller values for matched metal punching. To account for the typical tolerance and prevent sealing complications in lidding with Tyvek options, the Tyvek should be oversized by 3/32” larger than the outer cut dimensions of the tray. 

With typical heat seal machines, the tray is held secure by a cutout hole in the nesting tray or gasket material. From there, the lidding is then contained by pins or spring pins within the nesting tray that are located 0.047” away from the flange of the tray and will not interfere with the tray itself unless it is out of tolerance.

Additional Design Features

Looking beyond mere size considerations, incorporating user-centric features into your packaging design can significantly enhance the overall interaction and satisfaction of the end user. These features go beyond the basic dimensions and delve into the realm of thoughtful design elements that prioritize ease of use and aseptic presentation, especially crucial in healthcare settings.

Corner Radii

One key design consideration is the incorporation of corner radii, which not only adds a touch of aesthetic finesse but also plays a pivotal role in user comfort. Rounded corners contribute to a smoother and more comfortable handling experience, reducing the risk of sharp edges that might pose a challenge, particularly in healthcare environments where user safety is paramount.


Peel tabs and lift tabs are another set of features that bring a practical dimension to user interaction. These elements are strategically placed to facilitate the easy and precise peeling or lifting of lids, ensuring that accessing the contents is a seamless process. In healthcare settings, where precision and hygiene are of utmost importance, these features contribute to a user-friendly experience while maintaining aseptic conditions.

Printed Symbols

Printed symbols are a powerful tool for communication within packaging design. Clear and intuitive symbols provide users with valuable information, guiding them on how to interact with the packaging effectively. Whether it’s indicating the direction to peel or offering instructions for optimal opening, these printed symbols serve as visual cues that enhance user understanding, particularly valuable in scenarios where language barriers may exist.

Tear Notches

Tear notches add an extra layer of convenience, allowing users to open the packaging with ease. These small, strategically placed notches provide a designated starting point for tearing, streamlining the opening process and minimizing the chances of accidental damage to the contents.

Striking the Right Balance

Creating the perfect lidding design is like putting together a well-tuned orchestra. It’s all about finding the right balance among various factors—product needs, manufacturing processes, distribution challenges, and customer expectations. This careful consideration ensures that the heat-sealed lid not only offers protection but also enhances the overall user experience, especially in healthcare packaging.

First up, we focus on the product’s specific requirements. Whether it’s maintaining a sterile environment, resisting external elements, or incorporating user-friendly features, the lidding design must align seamlessly with these needs for optimal functionality.

Then, we shift our attention to the manufacturing process. The chosen design should not only be technically feasible but also efficient in production. Understanding the capabilities of the machinery, materials used, and the overall workflow is key to creating a design that enhances the manufacturing process.

Next, we consider the challenges of distribution. The lid must withstand the bumps and knocks during transportation, storage, and handling, ensuring it maintains its protective qualities throughout the supply chain. A robust design ensures the product arrives intact and ready for use.

Customer requirements come into play as well. User-friendly features like easy-peel tabs, clear instructions, and aseptic presentation contribute to a positive interaction with the product. The lidding design should not just meet but exceed these expectations, particularly in healthcare settings where precision and ease of use are crucial.

Choose Technipaq

When it comes to top-notch healthcare packaging solutions, Technipaq is the standout choice. With a solid reputation for delivering cutting-edge solutions that seamlessly blend functionality and user experience, Technipaq is your go-to partner for custom die-cut lids, pouches, and meticulous lidding designs. We go beyond the ordinary, offering a reliable and innovative approach to packaging. Whether you’re looking for precision, reliability, or a touch of ingenuity, Technipaq has it all.

Elevate your sterile packaging game with Technipaq—a commitment to quality, innovation, and perfection in every detail. Choose Technipaq and begin building your custom heat-sealed lids today.