MedTech Manufacturing worked example
Medical Device Packaging Cost with sterile devices packaged per lot of 250 devices: a worked example
Suppose sterile devices packaged per lot falls to 250 devices. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate regulated packaging cost per production lot including sterile barrier materials, secondary packaging, labeling, and validation overhead.
The inputs for this scenario
- Sterile devices packaged per lot: 250 devices (the input this scenario stresses; the baseline uses 500)
- Pouch and tray material cost per device: 3.25 $ / device (held at the documented default)
- Fixed packaging setup cost per lot: 650 $ (held at the documented default)
- Packaging labor and QC release cost: 480 $ (held at the documented default)
Working through the calculation
- The calculation starts from the formula this tool documents: Total packaging cost = devices packaged × material cost per device + fixed packaging costs + packaging labor and quality cost.
- Total lot packaging cost works out to 1,943 $ at these inputs, and this is the headline figure for the scenario.
- Packaging cost per device works out to 7.77 $ / piece at these inputs.
- Total packaging material cost works out to 813 $ at these inputs.
- Fixed costs plus packaging labor works out to 1,130 $ at these inputs.
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 29.49% below the baseline at 1,943 $.
- It computes total lot packaging cost as devices times per-device material plus fixed setup plus packaging labor and QC, then divides by device count for cost per unit. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.
Results at a glance
- Total lot packaging cost: 1,943 $ (headline result)
- Packaging cost per device: 7.77 $ / piece
- Total packaging material cost: 813 $
- Fixed costs plus packaging labor: 1,130 $
Run it with your numbers
- To rerun this with your own numbers, open the live Medical Device Packaging Cost calculator, set sterile devices packaged per lot to your actual value, and adjust the remaining inputs to match your operation.
Last reviewed 2026-05-12.