A method for making sterile suture packages employs a frame assembly line, a sterilization line and a blanker/cartoner line. A web of foil (W) is advanced in a series of movements through the frame assembly line to assemble a frame (B) containing needle-suture assemblies (C) in a plurality of cavities (D) in the frame, the frame having top (E) and bottom (F) aluminum foils with heat seal coatings on their facing surfaces. The cavities are formed in the bottom foil of each frame by a combination of pressurized air and mechanical plugs (124) which are forced against the bottom foil and an underlying die having recesses (112) for defining the cavities. A blanking operation following sterilization and sealing separates individual packages, each containing one needle-suture assembly, from the frame. The packages are then conveyed by belts through inspection stations and reoriented for loading into shipping cartons.