At Vonco, we receive frequent inquiries from medical device manufacturers looking to move away from PVC – and it’s easy to understand why. As sustainability becomes a critical focus across the healthcare industry, companies are reevaluating long-standing material choices. PVC, once a mainstay for products such as IV bags, catheters, and tubing, is now under increased scrutiny due to its potential long-term impacts on both human health and the environment.
While PVC has historically been favored for its durability and low cost, growing evidence highlights significant environmental and health concerns associated with its use. Derived from petroleum and chlorine, PVC often requires the addition of plasticizers such as phthalates to achieve the flexibility needed for medical applications. These additives have been linked to endocrine disruption and other serious health risks. Additionally, the manufacturing and disposal of PVC can release dioxins – among the most toxic substances known. For an industry committed to protecting human health, the continued use of such materials presents a serious and growing concern.
PVC is also not readily recyclable, which makes it especially problematic for waste management. This material contributes to landfill overload and can hinder circular economy goals.
In an industry dedicated to improving patient outcomes, the use of materials with known environmental and health risks presents a growing contradiction. Increasingly, medical device manufacturers are recognizing the need for safer, more responsible alternatives. At Vonco, we are proud to support this shift by providing innovative solutions that go beyond regulatory compliance – solutions that prioritize long-term human and environmental health. For us, sustainability isn’t an add-on; it’s a core principle built into every product we deliver.
Sustainable Alternatives: Biopolymers and Recyclable Barrier Materials
Emerging materials and technologies are tackling these challenges head-on. Here are two promising alternatives:
- Biopolymers: Derived from renewable sources like corn starch, sugarcane, or cellulose, biopolymers offer a biodegradable or compostable path forward. Materials like PLA (polylactic acid) and PHA (polyhydroxyalkanoates) are being tested for medical applications, although further work is needed to meet stringent sterility and shelf-life standards.
- Recyclable Barrier Films: High-barrier mono-material films made from polyethylene or polypropylene are gaining popularity. Unlike multi-material laminates that can’t be separated for recycling, these new films deliver necessary protection while being compatible with existing recycling streams.
Advanced sealing technologies, antimicrobial coatings, and oxygen or moisture scavengers are also being integrated to boost the performance of these greener materials.
Case Study: Accelerating Market Readiness for a Non-PVC Negative Pressure Wound Therapy Device
At Vonco, we specialize in turning complex packaging and fluid delivery challenges into production-ready solutions. When an OEM developing a cutting-edge Negative Pressure Wound Therapy (NPWT) device needed a fast, flexible non-PVC manufacturing partner – they turned to us.
The goal: bring a life-improving NPWT system to market quickly, safely, and at scale.
Our team collaborated closely with the OEM to co-engineer a multi-functional device component: a fluid bag with an integrated tube set capable of handling high-viscosity wound exudate. Vonco’s design-for-manufacturing expertise helped the client avoid delays by proactively addressing production hurdles and performance requirements during development.
From rapid prototyping to full-scale cleanroom production, we delivered a turnkey non-PVC solution that met ISO 13485 standards and exceeded the client’s expectations for both functionality and speed.
The result? A customized fluid delivery system that was key to launching the NPWT device – on time, on spec, and with confidence.
Want to learn how our custom manufacturing capabilities and PVC-alternative materials can help accelerate your next medical innovation? Read the full case study here
Why It Matters
Switching to sustainable medical device materials is no longer just a compliance exercise. It’s a strategic differentiator. Medical device companies that embrace innovation in this space stand to benefit in multiple ways:
- Regulatory readiness: Anticipate and align with evolving environmental regulations.
- Brand trust: Strengthen reputation with consumers, healthcare providers, and investors.
- Operational efficiency: Reduce packaging complexity and material waste.
Sustainability doesn’t have to come at the cost of performance. In fact, with the right partners and a forward-thinking mindset, it can drive long-term value.