Finishing the job: Spectrum Plastics Group transitions from component provider to complete finished device assembly contract manufacturer


Bringing a medical device to market can take years and requires expertise from several different perspectives and sources. From research and development to material selection and regulatory considerations, there are many parts of the process. When it comes to manufacturing the device, components of the finished product also come from a variety of sources before it is assembled. In some cases, parts of the device are outsourced to a manufacturer with a niche capability or area of expertise to streamline efficiencies and improve margins.


In other cases, selecting a contract manufacturer with a varied set of capabilities—from component manufacturing to complete device assembly—is far more beneficial. This was the case when a well-known manufacturer of fluid administration sets was planning to start the manufacturing process for an upcoming product. With a number of products already being manufactured at this facility, adding a new product on the floor was proving difficult. Faced with the possibility of outsourcing the manufacture of legacy products to make room for newer, higher-margin devices, the company sought an alternative solution. The company needed a trusted, full-service contract manufacturing partner.


Spectrum Plastics Group had been a longtime partner of this manufacturer, providing medical tubing components for fluid administration sets. With more than 60 years of experience, Spectrum Plastics Group is the largest extruder of conventional and advanced medical tubing in the market. From high-volume capacity to small batch specialty product capabilities, Spectrum Plastics Group manufactures medical tubing featuring catheter extrusions, single- and multi-lumen configurations, microbore size precision and tolerances, co-, tri- and multiple layered extrusions, paratubing, braiding and wire encapsulation. Materials range from PVC to polyurethanes to nylon copolymers, polycarbonate and PEEK to silicone. Regularly delivering extruded medical tubing manufactured to precise, larger diameter specifications required for fluid administration sets, Spectrum Plastics Group created consistency in product and a valuable relationship with the manufacturer. Nurturing that relationship became mutually beneficial when the manufacturer needed additional support in the form of contract manufacturing.


Recognizing that Spectrum Plastic Group’s expertise and rigorous internal acceptance standards are also applied to all processes, the manufacturer selected Spectrum Plastics Group to do more than manufacture components. In addition to manufacturing the medical tubing, Spectrum Plastics Group is now the complete contract manufacturer of the fluid administration sets, from mold making to device assembly.


Tom Flannery, Director of Business Development for Spectrum Plastics Group explains how the manufacturer was able to shift the perspective of Spectrum Plastics Group as a component provider to full-service contract manufacturer.


“We understood the pain point. The business climate for manual assembly is challenging, with policy initiatives that favor bulk, commoditized health care as opposed to patient- and outcome-focused care. Manufacturers, like health care providers, are trying to provide as much as possible, to as many as possible, for the lowest possible cost,” said Flannery. “That is why finding a contract manufacturing partner becomes so important. We become your partner from R&D stages, to manufacturing components and finished devices, to sterilization and packaging, and even managing the complicated and ever-changing regulatory environment.”


Transitioning the manufacturing and assembly of the finished device to Spectrum Plastics Group’s Reynosa facility in Mexico, Spectrum helped to streamline the manufacturing process helping the manufacturer gain back 10,000 square feet of space that could be dedicated to the new device. In addition, the overall cost of goods was reduced by 20% and the partnership came together much faster than anticipated, moving from the audit to the first purchase order in just 90 days.


The Spectrum Plastics Group Reynosa facility specializes in OEM plastic components, subassemblies, finished sets, coiled dispensers, contract manufacturing and folding drapes. The facility features 50,000 square feet of space, 20 assembly lines, 10 molding lines and an in-house tooling center with ISO 9001 and ISO 13485 certifications.


Results—By The Numbers:

  • Reallocated 10,000 square feet of manufacturing space
  • Reduced the cost of goods by 20%
  • Moved audit to purchase order in just 90 days


About Spectrum Plastics Group:

Owned by Kohlberg & Company and based in Alpharetta, Georgia with multiple plants across the United States, Mexico, Costa Rica, Ireland and Malaysia, Spectrum Plastics Group is a North American leader in the design and manufacture of custom and specialty medical plastics products focusing on niche, high value-added end markets. The group offers a full range of custom design, engineering and fabrication services, as well as meets the requirements of ISO 9001, ISO 13485, ITAR, FDA, operating multiple Class 7 & Class 8 clean rooms. For more information, visit www.spectrumplasticsgroup.com, or contact 404-564-8560.


Spectrum Plastics Group has been offering custom packaging solutions for more than fifty years.


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