Nelipak expands healthcare packaging footprint with Merrill’s acquisition

USA – Nelipak Corporation, a global supplier of healthcare packaging, has acquired Merrill’s Packaging, a firm known for custom thermoformed solutions in medical devices and pharmaceuticals. 

The deal, completed on December 8, 2025, adds production facilities in Burlingame, California, and Alajuela, Costa Rica, both holding ISO 13485 certification and featuring ISO Class 8 cleanrooms.

Merrill’s, established in 1961, has built expertise in thermoforming for life sciences and other high-demand sectors. 

The company also provides die-cut pouches, mounting cards, and services like design, development, and tooling. Its expansion into Costa Rica began in 2010, followed by a larger site opening in 2024 to meet rising needs.

Pat Chambliss, Nelipak’s CEO, expressed enthusiasm about the integration. He stated that the company values Merrill’s growth record and customer dedication. 

Chambliss noted that Nelipak gains from the team’s skills, thermoforming operations, client ties, and strategic locations in California and Costa Rica.

Rick Schulz, CEO of Merrill’s, described the move as a key step forward. He said it opens doors to Nelipak’s worldwide resources and range of rigid and flexible products, enabling fresh approaches to client needs.

This acquisition increases Nelipak’s manufacturing capacity in key innovation centers for healthcare. 

The combined operations now support sterile-barrier packaging for diagnostics, drug delivery, and related fields. 

Nelipak maintains in-house prototyping, validation, and lab services, alongside tray sealing equipment, to advance packaging development.

With more than 1,600 employees across 14 global sites, including eight in the Americas, five in Europe, and one in Asia, Nelipak focuses on cleanroom production standards. 

The addition of Merrill’s enhances access to these capabilities for existing clients.

In a related development, Huhtamaki expanded its sustainable medical packaging line in Europe last month, introducing recyclable thermoformed trays made from 50% post-consumer resin. 

The initiative, valued at US$15 million, targets pharmaceutical firms aiming to cut plastic waste by 30% in supply chains. 

Company officials reported that the trays maintain barrier properties for sterile applications while processing through standard recycling streams.

Early assessments show the merger preserves Merrill’s workforce of over 200, with plans for cross-training in sustainable materials.

Schulz added indirectly that employees will see expanded career paths through Nelipak’s network. 

The transaction, estimated at US$45 million, funds further tooling upgrades at both facilities.

Nelipak leaders plan to phase in eco-friendly polymers across the new sites by mid-2026, drawing on Merrill’s design expertise.

This step supports broader efforts in the sector to meet regulatory demands for traceable, low-impact packaging. 

As healthcare manufacturing shifts to hubs like California’s Silicon Valley and Costa Rica’s medical corridor, such moves ensure reliable supply for devices and biologics. 

Nelipak’s enhanced setup positions it to handle complex orders, from custom prototypes to high-volume runs.

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