MedTech Manufacturing worked example

Medical Device Packaging Cost with sterile devices packaged per lot of 1,300 devices: a worked example

This scenario runs the medical device packaging cost calculation on the strong side: sterile devices packaged per lot of 1,300 devices, with every other input held at its documented default. Use this when costing packaging operations, comparing sterile barrier systems, or budgeting packaging validation for new product introductions.

The inputs for this scenario

  • Sterile devices packaged per lot: 1,300 devices (raised for this scenario; the documented default is 500)
  • Pouch and tray material cost per device: 3.25 $ / device (unchanged)
  • Fixed packaging setup cost per lot: 650 $ (unchanged)
  • Packaging labor and QC release cost: 480 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total packaging cost = devices packaged × material cost per device + fixed packaging costs + packaging labor and quality cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 5,355 $ for total lot packaging cost, the number this scenario is built around.
  • At this operating point the engine returns 4.12 $ / piece for packaging cost per device.
  • At this operating point the engine returns 4,225 $ for total packaging material cost.
  • At this operating point the engine returns 1,130 $ for fixed costs plus packaging labor.

How this compares with the baseline

  • Against the tool's baseline example, where sterile devices packaged per lot sits at 500 devices and the headline result is 2,755 $, this scenario comes in 94.37% above the baseline at 5,355 $.
  • Use it when quoting a packaging job, sizing a lot to dilute fixed setup, or comparing in-house packaging against a contract sterilizer or 3PL. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total lot packaging cost: 5,355 $ (headline result)
  • Packaging cost per device: 4.12 $ / piece
  • Total packaging material cost: 4,225 $
  • Fixed costs plus packaging labor: 1,130 $

Run it with your numbers

  • Every input above is editable in the live Medical Device Packaging Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.