Packaging for surgical stapler buttress

A packaging assembly for one or more buttresses configured for use with a surgical stapler, wherein the packaging assembly comprises:

• (a) an outer tray;
• (b) an inner tray configured to selectively retain an applicator, wherein the applicator is configured for selectively retaining the one or more buttresses, and for loading the one or more buttresses onto an end effector of the surgical stapler, wherein the inner tray includes a base and a flap hingedly coupled with the base, wherein the base is configured to selectively retain the applicator, wherein the flap has a guide feature configured to engage and maintain the applicator in a longitudinally aligned orientation in which an open end of the applicator is aligned with a proximal end of the base, wherein the guide feature is configured to prevent the flap from closing fully against the base when the applicator is not in the longitudinally aligned orientation;
• and
• (c) an impermeable material positionable between the outer tray and the inner tray, wherein the impermeable material surrounds the applicator selectively retained by the inner tray forming a hermetic seal around the inner tray and applicator.

A method for packaging an applicator having a buttress assembly configured to be loaded onto an end effector of a surgical stapler, the method comprising:

• (a) positioning the applicator within a base of an inner tray such that a proximal end of the applicator is longitudinally aligned with a guide feature of a movable flap;
• (b) securing the movable flap in a closed position relative to the base, wherein in the closed position the movable flap is retained against the base of the inner tray by one or more mechanical fastening features, wherein the one or more mechanical fastening features includes first and second mechanical fastening members that releasably engage one another in the closed position with the applicator properly positioned within the base;
• (c) positioning the inner tray with the applicator between a first foil layer and a second foil layer;
• and
• (d) attaching the first foil layer with the second foil layer to define a foil assembly that surrounds the inner tray with the applicator to create a hermetic seal around the inner tray with the applicator.