… for a greener world
You would not be surprised to be told that your banana was ‘made’ entirely in its skin! Mother-nature is very efficient and would not consider growing a banana, then a skin, then placing the banana in the skin and then ‘zipping’ it up. But that’s what we human manufacturers do … we make a product then decide how to wrap it up and waste time and materials doing that.
Finding a better way inspired by nature
At Daysoft we make contact lenses and, yes, we make them then package them in plastic ‘blister-cups’ as does every other contact lens producer. However, taking a clue from the humble banana we decided to make our lenses entirely inside the plastic ‘skin’ we sell them in. Now, after several years of research, Daysoft engineers have invented a technology allowing us to make contact lenses entirely inside the concave blister-pack … just like mother-nature does when growing the humble banana. The lens is never handled during manufacture, is never inside another container (so never damaged being transferred into a separate blister-pack), never exposed to any liquid until it’s hydrated in saline in its blister-pack then sealed in foil and sterilised. We call our widely patented process INPAC® Technology
The size of the challenge
Modern soft contact lenses are fragile, being more than 50% water. The centre thickness is less than a human hair. The diameter is 140 times this thickness. The contour shape has to provide precise power-correction within tight limits and it has to be strong enough to support its weight in air even when fully hydrated with water. It has to be crystal clear, without imperfections so as to sit comfortably on the human eye.
It is not surprising therefore that the tradition way of manufacture is that, having made and checked the lenses, they are then lifted from their moulds and transferred into blisters, which have been made separately, before sealing and sterilising the lens inside. Now INPAC® removes all that handling; the lens is formed, hydrated, sealed-in and sterilized-in its originating mould.
The phased launch started in late 2018 coinciding with increased awareness of the need for everyone to radically reduce waste plastic. INPAC® does just that. When fully rolled-out by us into all our markets Daysoft will save the production of over 80 million Daysoft blister packs a year and the labour-intensive transfer of the same number of contact lenses from one production moulding into the consumer blister-moulding because they are now one-in-the-same.
Global benefits …. 14 Billion fewer plastic blisters every year
The potential global environmental benefits are huge. World-wide, 14 Billion contact lens blister-packs are made each year using around 14,000 tons of plastic using wasteful designs similar to that SHOWN left.
With INPAC® Technology applied to all contact lens manufacture the amount of plastic used in blister production would be … zero!
Approved by: Mother Nature