Method for packaging medical containers

A method for packaging a plurality of vials each including a head side and a based side for transportation in a tray within an evacuated internal cavity of an air impervious flexible film, the method comprising the steps of:

• a) inserting each of the vials into the tray with their head side proximate a floor of the tray;
• b) inserting the tray filled with the vials and a rigid sheet into the internal cavity;
• c) evacuating the internal cavity to a predetermined vacuum pressure such that the flexible film surrounds and engages at least the rigid sheet and the tray;
• d) sealing the flexible film such that the predetermined vacuum pressure is generally maintained in the internal cavity;
• e) transporting the sealed and evacuated flexible film, the rigid sheet, the tray and the vials to a filler;
• f) opening the internal cavity by tearing the flexible film at a tear notch;
• g) moving the tray, the vials and the rigid sheet out of the flexible film;
• h) inverting the rigid sheet, vials and tray;
• i) placing the rigid sheet, vials and tray on a support surface such that the base sides of the vials are resting on the rigid sheet;
• j) moving the rigid sheet from beneath the base sides such that the base sides are resting on the support surface;
• and
• k) moving the tray vertically away from the vials.