The blister packaging machine is popular in many industries. It packs items in blisters, making it suitable for food, pharmaceuticals, and many other products, including hardware. Below, we explain what it is and how it works, including its parts. We will also look at its different types and typical uses.
What is a Blister Packaging Machine?
A blister packaging machine is a device that seals products in pre-formed pockets. These pockets are the “blisters”. They protect the contents from damage, contamination, oxygen, and sometimes UV light.
These machines are form-fill-seal packers. They create the blisters inline, load them with the required product, and seal the chambers with protective materials.
They are also available in various forms, differing in size and automation. For instance, it can be a manual, semi-automatic type, or fully automatic device.
Blister packaging offers various benefits, making the device one of the most used packers in manufacturing. The advantages include the following:
- Ability to pack your products in transparent pockets for display and visibility
- It allows high-speed packaging for large-scale production needs
- The package has sufficient space for printing and other features
- You can use it to produce tamper-proof packages or dosages
- The pockets offer excellent mechanical protection and barrier properties
Parts of a Blister Packaging Machine
Blister packing machines use various parts to form, fill, and seal. Their construction, therefore, comprises the following sections, arranged from the first to the last.
Material Winders
These hold the blister and lidding rolls, unwinding them during packaging. The blister material is usually a plastic, such as PVC or aluminum foil. On the other hand, the lidding material is foil, foil/plastic, or foil/paperboard.
Heating Station
This part heats the blister-forming sheet, making it pliable for shaping. Note that high-temperature warming is only necessary when using plastic. Cold-formed foil requires less heating and is usually a plug-assisted procedure.
Forming Station
The forming station molds the blister cavities using negative pressure or vacuum and sometimes “plug assists”. It typically has the molds arranged on a flat plate or drum and a vacuum pressure supply system linked to it.
Feeding Station
The feeding station loads the required product into the formed hollows or blisters. The product is either a pre-packaged or unpackaged item. The product flows from a hopper, while sensors help the control system ensure accurate filling.
Sealing Station
This section seals the blisters to complete the package. It receives the sealing material from the winder mentioned earlier and uses it to cover the filled voids. The sealing agent is typically a heat-sensitive adhesive.
Drive System
It refers to the electrochemical system that moves the various machine parts. It typically consists of motors, actuators, and other movers. Various electrical devices ensure the system powers safely while control electronics regulate its operation.
The Controls
The controls include buttons, switches, and a touchscreen if the packer is automatic. The screen is an intuitive HMI display with touch functions. It lets you configure the machine, monitor its processes, and diagnose faults.
Blister Packing Machine Working Principle
So, how does a blister packing machine work? Its operation is a five-step process. The steps include forming the blister and filling it with the product. The final step involves covering the package with a rigid or flexible material.
Step1:Blister Forming
The machine forms blisters using heat and pressure, cold-pressing, or heat and pressure. Some materials, such as rigid clamshell plastics, are challenging to shape. In such cases, the machine uses a plug to mold them.
Step 2: Product Filling
In this step, the machine places the product in the formed hollows. The process is continuous in automatic packers, which requires a product-feeding system to supply the items requiring packing.
Step 3: Blister Sealing
The blister sealing step covers the cavity with a protective material. This material is usually a plastic sheet, paper, aluminum-based foil, or a combination of materials. Sealing utilizes heat to activate the adhesive and pressure for strength and durability.
Step 4: Slitting and Cutting
The slitting station cuts the continuous packaging into desired sections while cutters reduce the packs into desired units. These actions size the blisters for additional steps like cartoning. The material is now ready for coding and other procedures.
Step 5: Printing and Inspections
After heat-sealing, the blister card/strip undergoes other processes like printing, embossing, or perforation. The printed information includes batch number, date, etc. The packages also undergo visual inspections to identify flaws before further packaging steps.
Types of Blister Packing Machine
Blister packing devices come in varying designs. We mainly classify them by the type of blister-forming component, which can be a roller, flatbed, or both roller and plate. Based on this categorization, we have the following types.
Roller Blistering Machine
The roller type uses a drum-like component to heat and form the blisters. This design makes the machine easy to operate. The roller also consumes less power than a flatbed and relies on vacuum pressure to create the voids.
Flatbed Blistering Machine
Unlike the roller type that utilizes a drum, the flatbed type forms the blisters on a flat plate using positive pressure. These packers are usually large systems with multiple stations. They suit large-scale packaging, offering high production speeds.
Roller Plate Blistering Machine
This type combines a roller and flat bed in its construction, offering the advantages of both types. The plate forms the blisters while the drum seals them after filling. This construction makes the device highly adaptable, high-speed, and suitable for industrial settings.
What is a Blister Packaging Machine Used For?
The blister packaging machine is everywhere today, given its many benefits. You can virtually use it in any sector, provided the product can fit in the thermoformed enclosures. The following are example applications by industry type.
Cosmetics Industry
The machine is helpful in cosmetics, where it manufactures and fills skincare packaging. It offers various benefits, such as enhanced speed and the ability to package different items. We use it to package the following personal care items.
- Makeup sets
- Skincare products
- Hair care products
- Beauty accessories
- Fragrance bottles
Pharmaceutical Products
The device is most popular in the pharmaceutical industry. This packaging features brittle backing and collapsible blisters for item extraction. It can also help dose medications or make packages tamper-resistant. Example uses include packaging these pharma products.
- Capsules
- Pills
- Tablets
- Ampoules
Consumer Goods
Manufacturing companies use it to package various consumer items. The material in this application is usually thicker for structural integrity and transparent for product visibility. The goods you can package with this machine include:
- Tools
- Electronics
- Kid toys
- Batteries
- Toothbrushes
- Electrical devices and other hardware
Food Products
You can also use it to package a wide range of foods. This application has varying options depending on the food type and preservation method. The following are examples of what you can pack with the help of this packaging solution.
- Snacks
- Candy
- Chocolate
- Chewing gum
Medical Devices
This application involves packing medical devices in securely packaged housings. In most cases, these are disposable products requiring high sterility levels. The following are popular examples of items you can pack in thermoformed plastic pockets.
- Syringes and needles
- Catheters
- Medical gauze
- Filters
- Surgical kits
- Transfusion sets
Blister Packing Machine Specifications
Blister packaging machine suppliers provide a list of specifications alongside each product type and model. These make the selection process easier for buyers. We compiled a list of the specifications and what they mean for your needs.
Packaging Speed: the speed indicates how many blisters the machine can form and seal per hour. Use this feature to determine what best fits your needs.
- Range: 1,200–12,000 blisters/hour
- Desktop models: 1,200–2,400 blisters/h
- Pharmaceutical-grade: Up to 12,000 blisters/h
- Selection Guide:
- <500,000 blisters/month → Choose ≤6,000 blisters/h models
- 1 million blisters/month → Opt for ≥8,000 blisters/h systems
Packaging material: it tells you the materials you can use, which mainly depend on the types of blister packs. It also varies by content type and desired protection levels.
| Material Type | Thickness/Weight | Example Application |
|---|---|---|
| Forming Films | ||
| – PVC | 0.2–0.5 mm | Medical tablet packaging |
| – PET/PP composites | 0.25–0.6 mm | Food-grade barriers |
| Lidding Films | ||
| – Aluminum foil | 20–40 μm | Moisture-sensitive drugs |
| – Cold-seal coatings | 60–80 gsm | OTC product packaging |
Automation level: it specifies whether the device is a manual type, semi-automatic, or fully automatic.
| Type | Speed Range | Key Features |
|---|---|---|
| Manual | <1,000 blisters/h | Human-dependent loading (ZBL-420) |
| Semi-automatic | 3,000–6,000/h | Auto-sealing + manual feeding |
| Full-automatic | 8,000–12,000/h | Robotic integration (IMA B144) |
Power Needs: the kind of power sources it uses and their levels. The power is usually electric (voltage and watts) and pneumatic pressure (Pascal or other units).
- Electric:
- Voltage: 220V (small) / 380V 3-phase (large)
- Power Consumption: 2 kW (desktop) – 20 kW (production line)
- Pneumatic:
- Pressure: 0.6–0.8 MPa (6–8 bar)
- Air Consumption: 100–500 L/min
Physical Dimensions: these show the machine’s size, including its weight. It tells you how large or small it is and whether it can fit your facility.
| Model Type | Dimensions (L×W×H) | Weight | Space Requirement |
|---|---|---|---|
| Desktop (HTB-300) | 1.2m×0.8m×1.5m | 500 kg | 2m² floor space |
| Full-auto (IMA B144) | 6m×3m×2m | 3,000 kg | 20m² with maintenance access |
Conclusion
The blister packaging machine is a versatile device with many uses. It forms depressions to hold products and seals them for protection. Understanding how it works is essential if you plan on buying it for your business. That’s because the device is available in various types, each suiting specific uses.
