10 Wound Care Converting Challenges That Impact Quality, Cost, and Scale
Wound care manufacturing can be full of minefields for OEMs and contract converters. Extensible materials stretch, layers must align precisely, and every process must be validated. If all these variables aren’t controlled in real time, then production efficiency and product quality suffers.
We sat down with Delta ModTech’s Ben Tremblay, a Market Segment Specialist at Delta ModTech, where he works closely with converters to evaluate complex applications and align converting technologies with real production needs. He brings a practical, customer‑driven perspective shaped by hands‑on experience across precision and medical converting environments.
Key takeaways
- Wound care problems are driven by material behavior, not just machine capability.
- Most problems are the result of poor process design, not just equipment functionality.
- Inline verification and process control are critical to reducing waste and risk.
1. Web stretch and material distortion
Wound care products rely on extensible materials like adhesives, films, foams, and non-wovens. If those materials stretch during converting, they relax after cutting and parts fall out of spec.
This challenge typically shows up as:
- Parts shrinking or deforming after die cutting
- Inconsistent dimensions across runs
- Increased scrap due to out-of-spec product
Boyd Technologies experienced it with one of their early-stage prototypes. “The adhesive was very sticky, and the film was stretchy,” said Bobby Schroeder, a development engineer. “That’s where some of the problems came in handling it and maintaining tensions during production.”
The core issue is how the entire system handles material behavior in real time.
“You need to be adept at fine-tuning the processes and the equipment to be able to handle those sorts of materials.”
Ben tremblay, delta modtech
2. Holding tight tolerances with extensible materials
Stretchable substrates, adhesives, and multilayer builds all introduce the kind of variability that makes tension control a nightmare. What worked for Boyd Technologies won’t necessarily work for everyone. Maintaining tight tolerances will be dependent on material and applications.
However, as Ben Tremblay explains, “Utilizing things like closed-loop tension control with transducers, and closed-loop feedback on vision systems can keep those tolerances as tight as possible.”
3. Maintaining precise multilayer alignment
Most wound care products are multilayer laminates. Each additional layer increases the chance of misregistration. When alignment isn’t controlled continuously, you’ll see:
- Layer-to-layer drift over long runs
- Functional defects in the final product
- Increased rework or rejected batches
Ben says the solution is to use registration as you build layer upon layer, adding closed-loop vision system(s) to check and make changes to automatically maintain nominals.
4. Poor utilization of high-cost wound materials
Material cost is one of the biggest drivers in wound care production. Small inefficiencies add up quickly and can impact your cost per part.
The efficiencies result with optimizing your layout, spacing, and cutting strategy. “For example, we can reduce or eliminate waste material via island transfer or island placement,” Ben explains, “which gives you high utilization of your raw materials, in high-volume production.”
5. Verifying quality without slowing production
Balancing quality and throughput is one of your biggest challenges. It also has the highest stakes. This is where the combination of the right process and high-performance equipment truly shines. Rely on systems such as:
- Inline vision systems to detect defects
- Real-time measurement and verification
- Automated reject systems to remove bad parts
This approach ensures only verified products move forward, without creating a bottleneck. LAMATEK™ did this, using a modular machine vision-system that helped to achieve a tight tolerance of .015.”
6. Eliminating inefficient multi-step processes
Many wound care products are still manufactured across multiple machines and steps. That creates unnecessary handling, variability, and labor.
“There are definitely times where processing the complete product in-line, in one pass, can save time and money, but it’s going to be application-dependent,” Ben says.
7. Scaling from prototype to production
What works in development often breaks in production. Common breakdown points include:
- Rebuilding the process between R&D and production
- Loss of critical process parameters
- Inconsistent repeatability at higher speeds
The more effective approach is developing and scaling on the same platform so “you’re only doing process development once,” as Ben explains. “There’s a huge advantage to being able to do research and development on the same equipment that you’re running at high volume.”
“Do process development once.”
ben tremblay, delta modtech
One manufacturer doubled their speed to market through this process, adapting to over 30 dynamic changes to the product as it was developed.
8. Managing risk in a regulated environment
Wound care manufacturing must meet strict regulatory requirements. Every process needs to be validated, documented, and repeatable.
When validation is treated as a late-stage step, it slows everything down. When it’s built into process development from the beginning, risk is reduced and timelines improve.
9. Lack of process-specific experience
Wound care sits at the intersection of coating, converting, laminating, and packaging. Without the right experience, teams often encounter:
- Trial-and-error development cycles
- Missed potential failure modes early in the process
- Slower time to validation and production
Even advanced equipment can’t compensate for gaps in process knowledge and experience. Ryan Cribbin of Tapecon notes that Delta teams “run through a Rolodex of ideas,” many of those built off proven recipes.
10. Deciding whether to upgrade equipment or improve the process
Not every issue requires a new machine. In many cases, the limitation is the process and not the equipment. The challenge is understanding what’s possible and identifying whether improvements can be made within the current system.
It really comes down to total cost of ownership, and determining the upfront costs, overall equipment effectiveness, and the benefits of overall improvement to your company’s bottom line – and to its culture.
Bringing it together: How problems get solved
These challenges fall into three areas: material behavior, process design, and risk management.
They’re all connected. If materials aren’t controlled, alignment fails. If the process isn’t designed correctly, waste increases. If validation isn’t built in early, scaling slows down.
That’s why solving wound care manufacturing problems requires more than equipment. It requires a partner that can help you develop a process – one that works from development through production.
Case studies cited in this post:
This Global Manufacturer Nearly Doubled Their Speed to Market for a Groundbreaking Project
LAMATEK™ Relies on Delta ModTech Support to Turn Potential into Performance
How Boyd Technologies Uses Delta ModTech to Move Products From Prototype to the Marketplace
FAQs
Why is wound care manufacturing more complex than other converting applications?
Wound care products use stretchable, multilayer materials that require precise alignment and tight tolerances. These variables make the process more sensitive to small changes.
What causes most defects in wound care production?
Common causes include material stretch, misalignment between layers, and lack of real-time process control. These issues often compound as production speeds increase.
Why is scaling from prototype to production so difficult?
Many processes are developed in isolation during R&D and then rebuilt for production. Without continuity, variability increases and validation becomes more difficult.
Do all improvements require new equipment?
Not always. In many cases, process improvements or modular upgrades can deliver significant gains without requiring a full machine replacement.
