Dual-Cartridge Packaging System for Two-Component Silicone Materials

Challenge

A manufacturer producing diagnostic medical devices required a two-component silicone compound used to encapsulate sensitive electronic sensors. The material provided environmental protection and mechanical stability for delicate electronics within the device.

The silicone was supplied as a two-component formulation with a limited pot life after mixing. Once mixed, the material had to be used quickly before curing began.

This created several challenges within the production environment:

• wasted material due to expired mixed silicone
• inconsistent mixing ratios during manual preparation
• interruptions to assembly operations while new batches were mixed

The manufacturer needed a packaging configuration that would allow technicians to mix and dispense the silicone directly during assembly while maintaining precise component ratios.

In addition, silicone materials introduce potential cross-contamination risks in manufacturing environments. Silicone oils can migrate or bleed from certain formulations and contaminate equipment or nearby processes. Even small amounts of silicone contamination can interfere with other materials processed in the same facility.

Before accepting the project, JWV Solutions evaluated the specific silicone formulation to determine whether it posed a cross-contamination risk for the Altaris Industrial facility. This review included assessing the chemistry to ensure the silicone oils would not separate, bleed, or leach during processing. If the material had shown migration risk, production would have been considered for a separate or controlled processing environment.

Solution

After confirming the stability of the formulation, Altaris Industrial developed a dual-cartridge packaging system designed for two-component silicone materials.

Each cartridge contained precisely measured quantities of the base silicone and curing agent in separate chambers. The components remained isolated during storage and handling. When dispensed through a static mixing element, the materials combined automatically in the correct ratio.

This approach allowed assembly technicians to prepare material only when needed while eliminating manual mixing steps.

Results

• reduced material waste from expired mixed silicone
• improved assembly efficiency during device production
• consistent mixing ratios during dispensing
• simplified handling of sensitive encapsulation materials
• validated contamination-control procedures for silicone materials