Blister packaging is the most common format for oral solid dosage forms worldwide. Understanding how blister packing machines work helps you select the right machine and troubleshoot production issues.
The Blister Packing Process
1. Film Forming
The forming station heats a roll of PVC, PVDC, or Alu-Alu film and deep-draws it using tooling to form the blister cavities. Temperature and pressure control here directly determines cavity depth and uniformity.
2. Filling
Tablets or capsules are fed into the formed cavities. Feeding mechanisms include:
- Gravity feed with a vibratory track
- Brush feed for delicate products
- Pick-and-place robots for high accuracy
3. Sealing
A lidding foil (aluminium + heat-seal lacquer) is bonded to the filled forming film using a heated sealing roller. Seal integrity is critical for product protection.
4. Printing
Batch number, manufacturing date, and expiry date are printed onto the lidding foil in a separate printing station — typically using hot foil embossing or inkjet.
5. Cutting / Punching
The sealed strip is cut to the required blister size and format by a rotary cutting station or a punch.
Forming Film Types
| Format | Protection | Cost | Use Case | |--------|-----------|------|---| | PVC | Moderate | Low | General tablets | | PVDC | High (moisture) | Medium | Hygroscopic drugs | | Alu-Alu (cold form) | Highest | High | Sensitive compounds |
Choosing the Right Machine
Evaluate output (blisters/minute), forming film compatibility, format changeover time, and servo-driven vs. mechanical drive. Servo systems offer better precision and faster changeovers.
GentlemanPharmed supplies blister packing machines from entry-level (60 blisters/min) to high-speed lines (400+ blisters/min), all CE-marked and GMP-compliant.