Shock Pallet Development for Medical Device Transport

Our client is an established medical device manufacturer preparing to launch a new, high-value product into the global market. The equipment was designed for use in hospital environments and required a robust, compliant transport solution for international shipping, specifically to the United States.

The client needed a shock pallet that would:

• Safely protect a high-value medical device during transatlantic transport
• Meet stringent shock and handling requirements for hospital-grade equipment
• Be fully recyclable to align with sustainability goals
• Be easy to disassemble for efficient disposal and reduced waste
• Satisfy internal engineering teams across both Irish and US operations

With multiple stakeholders across two regions, achieving consensus while maintaining technical and sustainability standards was a significant challenge.

Our Approach

We worked closely with engineering teams from both the Irish and US offices to fully understand the product, shipping environment, and regulatory considerations.
Over the course of the project we:

• Developed 2 distinct shock pallet design concepts, each addressing protection, recyclability, and ease of disassembly
• Collaborated through multiple design reviews to refine and validate concepts
• Selected 3 designs for prototyping and physical testing, ensuring real-world performance under transport conditions
• Iterated designs based on test results and cross-functional feedback

The Solution

Following extensive testing and evaluation, a final shock pallet design was agreed and approved. The solution successfully balanced protection, sustainability, and usability while meeting the expectations of all stakeholders involved.

Project Timeline

The project took 14 months from initial concept to final approval. The extended timeline was largely due to the collaborative decision-making process involving engineering teams in both Ireland and the United States, ensuring the final solution met global requirements.

The Outcome

• A fully approved, recyclable shock pallet tailored to a high-value medical device
• Proven performance through physical testing and validation
• A long-term supply solution

Long-Term Partnership

Despite the length and complexity of the development phase, the success of the project is reflected in its longevity. Four years later, we continue to supply the client with the approved shock pallet, supporting the ongoing global distribution of their medical device

Key Takeaway

This project highlights our ability to manage complex, multi-stakeholder engineering challenges and deliver sustainable, high-performance packaging solutions that stand the test of time.