Nearly 1 in 10 adults around the world are diagnosed with diabetes. Given the prevalence of this disease, it should be no surprise that in the world of medical packaging, few categories have experienced as much evolution over the last few decades as diabetes care. What began as a system of vials and syringes has evolved into a high-tech and increasingly user-centric environment. From insulin pens to wearable pumps and continuous glucose monitors (CGMs), the packaging that houses and protects these devices has had to evolve just as quickly. Since I can remember, I’ve watched those I love navigate diabetes. From sitting next to my aunt as she checks her sugar regularly through finger pricks to helping my best friend weekly change the site of her insulin pump, diabetes has always been around me. Thanks to the industry advancements, I’ve watched these changes truly empower those with a disease with so much irregularity to live a fulfilling life.
From Syringes to Smart Wearables
In the early days of diabetes management, treatment was largely dependent on glass vials and reusable syringes. This required manual measurement and careful handling. This posed significant barriers for patients with dexterity issues or visual impairments, two common complications of diabetes. Packaging at this stage was utilitarian: designed primarily for sterility and protection, with little consideration for usability or portability.
Then, as pharmaceutical companies began introducing insulin pumps in the 1970s and insulin pens in the 1980s, the landscape shifted. In the last few decades an even more dramatic shift occurred as diabetic care options like insulin pumps and CGMs are now wearable technologies—many of which are connected to smartphones through an app. Now, patients have a more convenient, discreet, and personalized way to manage their insulin doses. And while the devices themselves are an incredible advancement in technology, their packaging must be just as thoughtful, particularly given the range of users and environments in which they are administered. The packaging now must be a solution that balances protection, ease-of-use, and clear instructions for self-administration.
Innovations in Protective and Functional Packaging
The move toward compact, wearable, and digital diabetes devices has introduced new challenges for sterile barrier packaging. Insulin pumps and CGMs include sensitive electronics and components that require protection not just from impact, but from temperature fluctuations, moisture, and storage.
To meet these needs, packaging engineers are exploring advanced materials and innovative ideas. Some of which include multi-layer barrier films, thermoformed trays, or mounting cards inside the packaging that can double as instructions for use—turning the package itself into part of the medical experience.
Human Factors Designed Packaging
Unlike many other patient populations, diabetics often interact with their medical devices multiple times a day. This high frequency of interaction means that packaging cannot be a secondary consideration. This is particularly important because diabetes isn’t just about insulin management; the disease is frequently accompanied by a range of complications that affect how users interact with packaging:
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Visual impairments: Diabetic retinopathy and other vision problems make it difficult for some users to read small fonts or distinguish low-contrast labeling. For packaging engineers, this requires careful use of things like typography, color contrast, and tactile features.
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Neuropathy and limited dexterity: Nerve damage, especially in the hands and feet, is another common condition. Packaging must be easy to grip, open, and manipulate—often with one hand or minimal fine motor skills. Tear notches, push-button dispensers, and common shapes can make a significant difference.
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Mental Workload: While not exclusive to diabetes, the need to manage a chronic disease 24/7 can lead to information fatigue. Clear, concise labeling and intuitive unboxing experiences are essential to minimize user error and support adherence.
A Focus on Sustainability and the Future
Diabetes is a lifelong condition. So, its packaging must account not only for patient needs but also for the environmental impact. With patients disposing of insulin pens, lancets, sensor applicators, and infusion sets regularly, there's increasing pressure to design for recyclability or reusability. Exploring biodegradable materials, smart tracking for waste reduction, or even ways to reuse can help maintain managed care while reducing waste.
As the tools for managing diabetes continue to advance, the role of the packaging will only grow in complexity and importance. Thoughtful, inclusive, and innovative packaging design isn’t just about protecting the product—it’s about empowering the diabetic.
