How to select Blister Packaging Machine for your pharma applications

What is a Blister Packaging Machine? 

Blister Packaging Machines are used to pack unit doses of pharma products, such as tablets, capsules, ampoules, and vials. The packaging takes the form of a blister, that's why the machine is so named. The medicine is stored in the blister, which becomes airtight and sealed, providing essential protection from the outside environment.

The product is packed between two packing materials that are manufactured in accordance with pharma regulations. There are two commonly used packaging materials, PVC and Aluminum.

There are three different combinations of packing material - ALU - ALU , ALU – PVC, and PVC  - PVC.  Decision to use specific packing material combinations depends upon the product requirements and is decided & verified by the quality department.

● In ALU - ALU type, the cavity is formed in the ALuminum packing material and is also sealed with ALuminum.

● In ALU - PVC type, the cavity is formed in the PVC material in which the product is placed and is sealed with aluminum.

● In PVC-PVC type, the cavity is made of PVC packing material and is also sealed with PVC.

Blister machine consists of  different sub-components  that have their definite function and contribute to the overall working of the blister machine.

Some common components include but are not limited to the following.

Feeding station  - it is used to feed the medicine in the cavity of the packaging material. Tablets from the hopper pass through the feeder into the cavities. There are different types of feeders depending on the application requirement.

Forming Station  - it is used to form the cavity in the packaging material.  Depending on the packaging material, vacuum or pressure is used to form the cavity.

Sealing Station  - it is used to seal the packaging material containing products with the upper layer packaging material. Sealing is performed by applying heat through heaters.

Cutting Station  - it is used to cut the sealed packaged blister into appropriate sizes. A die of appropriate size and physical specification is used to make the cutting in the packaging material.

The parts mentioned above are the most common ones. Some  models also include advanced features such as an inspection system and additional sensors, which come at an added cost. However, they also make the blistering operation and output product more reliable, safe, and high-quality

What can go wrong if the appropriate machine is not selected

Some consequences of not selecting appropriate  blister machine  include but not limited to the following

● The machine will fail to deliver the expected outcome, which will eventually affect the fulfillment of market orders.

● The resultant products will fail in leak tests, possibly due to incompatible machine parts specifications.

● The most important factor will be the company's reputation, which will reduce the market and product's efficacy.

● Incompatible utility specifications will  affect the performance of machine parts such as cavity forming and sealing, which will reflect in the final finished form.

● Rejected or waste blisters will float in the market and eventually into the hands of the patients.

Some tips to consider when selecting Blister Packaging Machines or your pharma application

Some points to consider when selecting a blister packing machine include, but are not limited to, the following.

Which type of product do you want to pack?

As mentioned earlier in the article, different types of products can be packed. Each product has its unique physical appearance and dimensions that require designing machine parts of unique specifications to pack qualitatively and acceptably.

Specification of parts for one type of product cannot be used for another product.

When specifying blister machine requirements, consider your product portfolio and determine which type of product you want to pack. Often, different classifications of products can be filled with a single machine, but they require their change parts. However, when the nature of product changes,  it requires a separate machine

For example, a machine designed to pack products can pack any type of product, such as capsules and tablets. However, it cannot pack ampoules or vials.

Which is the packaging material used?

As mentioned earlier in this article, there are different types of packaging material combinations, i.e., ALU and PVC. The mechanism to form a cavity and seal is different for both of them and cannot be used for both.

Specify your packaging material requirement when ordering machines from the supplier. It will help to develop accurate machine structures and systems required by the right packaging material.

What is the total output and speed

When ordering a new blister packaging machine, consider your market requirements or forecast. It will help to determine the total productivity of the machine.

If you are in the market for a considerable period, have a large market footprint, and are purchasing machines to increase your productivity, it is better to go for high-output machines. On the other hand, if you have a small market footprint or just starting in the market, it is better to go for a low-output machine.

Production or scale scale

Blister machines are used in both the production department and in laboratories for R&D purposes.

For production purposes, the output is generally higher, large physical dimension, high power and all other characteristics are high. On the other hand, lab-scale blister machines have lesser requirements, and have lower capacity, small physical dimension, and all other characteristics are lower.

For  production purposes, the lab scale cannot be used because it cannot meet the required production and product characteristics. Similarly, it is a waste of money and machine capabilities to use a production-scale machine for lab-scale applications. 

When buying a blister machine, consider which area you will use, i.e., either in the production area or lab area.

Inspection System

The inspection system is the latest technology where each blister pack is inspected for various defects, such as broken tablets or empty blisters. The inspection system automatically inspects the blister and  rejects the corresponding blister.

This system is an electromechanical system, where different electronic components, such as a camera and computer, are connected with mechanical components, such as a valve and actuator, to direct the rejected blisters into specific output channels. 

When selecting a blister machine, always consider whether you require  an inspection system or not. If your machine is high speed, the inspection system can be used. On the other hand, if your machine is low speed and production is less, the inspection system can be omitted.

Physical dimensions

Physical dimensions are the space or area occupied by the machine. Sufficient space should be available for operator movement, material, and other requirements.

Before selecting a machine from the supplier, make sure you have enough space to accommodate the machine and its necessities. If such considerations are not made, the area has to be re-shaped and re-designed to make the space available.

Automatic or semi-automatic

The blister machine's operating mechanism can be automatic or semi-automatic.

● In automatic type,  all sub-functions in the machine, such as feeding, sealing, and cutting, are performed automatically without human involvement. Using control automation components, such as PLC and HMI, enables automatic operations. It is usually faster than semi-automatic increased productivity and is also costly.

● In semi -automatic type, the machine's partial operation is performed automatically, while remaining are conducted automatically. Its productivity is less than as compared to the automatic one.

When selecting a machine, consider whether your requirements are automatic or semi-automatic. If you have a large market, require large production quantities, and are purchasing machines to increase your productivity, it's best to go for an automatic option.

On the other hand, if your productivity options are not as high, and you are tight on budget, go for a semi-automatic one.

Downstream equipment requirement

Down steam equipment is the one that is connected to the blister machine after a product comes out of the machine. Its main purpose is to increase the overall productivity of the packaging department of a pharma organization., by further automating the downstream operations. One example is carton packing, to pack  blister in cartons of various sizes.

Integrating downstream equipment requires mechanical, electrical & electronic components in the machine. These components are then connected to downstream equipment to synchronize their operation with the blister machine.

If you plan to connect downstream equipment with the blister packing machine, inform the machine manufacturer so that they can integrate additional components into the blister machine.

Some machine manufacturers include this as a part of standard machine options. While some machine manufacturers keep it optional at extra cost

Utility requirements

The blister packaging machine's performance is highly dependent on the available utilities. Because all major machine sections, such as forming, sealing, and cutting, are activated by pneumatic air. Additionally, blister machine areas also require precise environmental conditions because tablets are exposed to the area's environment.  Electric power is also a significant requirement because heaters use high electrical power to heat up.

When selecting a blister machine, determine which supplier uses all of the utilities available in your manufacturing facility. Additionally, consider special requirements, such as 120VC electrical power supply in contrast to 220VAC.