What Went Down at the[PACK]out™ 2025

Byline: Ryan Ott, Vice President of Quality, Packaging Compliance Labs

Were you with us in Coronado for thePACKout? Were you sadly unable to attend? For both camps, the world-class lineup of speakers, activities, and breakouts offered so much valuable insight, we’ve committed to keep the conversations going. Amid the three days of in-depth thought leadership, three topics emerged as frontrunners across the board: SIMULATION, STERILIZATION, and SUSTAINABILITY 

The presentations I was able to attend from the “packed” agenda (sorry, I couldn’t leave that alone) brought food for thought on how these trends are changing medical packaging engineering. 

Kelley Kuehne, Engineering Director at Medline Industries

I know I am not alone in confessing that, on multiple occasions, I’ve reached a point on a project where I want to throw up my hands. Why? Because I am once again thinking we’ve been doing the same thing, the same way for decades, for no compelling reason beyond it’s how we’ve always done it. Yet it is slow and drives up costs—the very factors we are perpetually fighting! Sterilization is one of the critical processes in medical device packaging engineering that can take far longer than desired to complete validations. 

I was energized by Kelley’s bold approach to ethylene oxide (EO) sterilization validation studies: the concept of using simulation technology to produce sterilization conditions at a lab. We are all too familiar with the process of building samples, shipping them off to be sterilized and waiting for them to come back as time ticks by. What if we could run a vacuum simulation for EO sterilization right in the lab with highly accurate results?  

Kuehne explored ways to avoid the constraints of traditional production settings by considering how EO interacts with packaging materials and what dynamic forces affect the sterile barrier during sterilization. Using actual visual imagery and data to demonstrate the unseen process, he pitted the status quo against emerging technology and processes. I, for one, was all in on this in-depth exploration of concepts that could reduce development cycles while maintaining unsurpassed standards in quality and safety.  

And what if such novel concepts effectively extend to other validations, further reducing cost and accelerating timelines? Another possible scenario had us considering the potential of  simulating distribution studies in-lab—again abbreviating timelines due to the back-and-forth of samples that were already shipped once and then repeating the process for the actual distribution study.  

Kuehne’s in-depth knowledge and illustrative applications may not yet be a real thing, but the potential for simulation in validation is certainly a real—and exciting—topic at the table.  

Nazli Ozdemir, PhD, Founder at Gulsine  

Another emerging pathway of simulation is undeniably AI. Nazli Ozdemir, PhD, took the stage to illustrate how AI software could elevate medical and bio tech packaging through predictive modeling with robust data and advanced inputs. She challenged us to consider how mathematical models and digital techniques can add value to empirical testing and eliminate traditional-method time sinks. Using AI and proprietary materials informatics, Nazli is focused on how AI, in the form of customized software and computer simulations, coupled with materials science can redefine shelf-life testing (and specifically polymer aging) with precision accuracy. The ability to improve on the enduring (and time-consuming) tradition of energy-demanding climatic chambers is long overdue. The prospect of reduced carbon emissions and energy conservation make a compelling case for AI and computer technology to enhance sustainability advancement in the medical packaging sector.   

Nestor Jarquin, Director Category Management – Surgical Instruments, Kaiser Permanente

As category owner for surgical instruments at Kaiser Permanente, Nestor Jarquin is the decision-maker for medical device purchasing across KP hospitals. Nestor said, at least for KP, if you, as a medical device packaging engineer, identify a sustainable option that does come with a cost, he wants to hear about it. He noted that he is willing to consider data and justification that can be presented to stakeholders. 

Since packaging has often been charged to find sustainability opportunities at no additional cost, Nestor’s new perspective as a voice from the provider side of the healthcare system was welcome news. Nestor called out a huge opportunity gap for packaging professionals noting that he did not see it himself until his introduction to the[PACK]out™. Until then, he admitted, he had no idea what we did or that our specialized mission even existed.  

As such, Nestor said that a total lack of understanding exists on the part of hospital purchasing decision makers like him as to the value innovative medical packaging brings. His advice was that packaging engineers start talking to commercial partners within their organizations to help them understand the value our work brings to the quality of the product. For me, it recalled a project I’d done creating a custom zip tie for effortless opening, no tools required. Unless that was specifically called out to the buyer as a value-add feature, they would settle for packaging that required wire cutters to open in the surgical setting. 

This is just a small representation of the compelling ideas from the[PACK]out this year. As a former packaging engineer and current Quality leader, I particularly enjoyed that the agenda was robust in its packaging focus, featuring doers, and plenty of technical thinkers, speaking to what they do and their perspectives. The choose-your-track breakouts and casual, comfortable boat outing made networking effortless and fun. Thanks to all who planned, executed and attended such a win-win event. Don’t miss it in 2026!