All-in-One Design: Integrates forming (PVC/PET/Alu), feeding, heat-sealing, punching, vision inspection and waste rewinding in a single frame; modular architecture allows line extensions or stand-alone operation.
Precision Thermal Control: PID closed-loop heaters keep sealing platen at ±1 °C, guaranteeing uniform blister wall thickness and zero cold-seal risk.
Universal Format Flexibility: Forming depth 6–30 mm, quick-change tooling (<10 min) for round/oval/irregular tablets, hard & soft capsules, syringes, vials, diagnostic cassettes.
Full Track & Trace: Industrial PC with 21 CFR Part 11 software records batch ID, temperature, pressure, foil reel number and exports to MES/ERP via OPC-UA.
Key Advantages
High Output: Continuous rotary models up to 450 cycles/min; intermittent plate models up to 180 cycles/min; OEE improved by 20 %.
Material Savings: Servo-driven pre-heating and optimized stretching cut PVC usage by 8 %; foil trim <2 mm.
Zero-Defect Guarantee: 100 % vision + check-weighing rejects missing tablets, broken blisters or black spots; field complaint rate <0.01 %.
Energy & Silence: All-servo drives consume <0.3 kWh per 1,000 blisters; noise ≤72 dB.
Global Support: 48-hour on-site response, AR remote maintenance, lifetime spare-part inventory; MTTR <4 h.
Typical Applications
Pharmaceutical Solid Dosage
Immediate-release and coated tablets (IBU, Metformin, Amlodipine) run at 300–400 blisters/min with ±2 % weight feedback; controlled-release cores use pre-heat forming to avoid shell cracking.
Enteric-coated pellets in size #3 HPMC capsules are blistered under nitrogen flush (<1 % residual O₂) for proton-pump inhibitors.
Orally disintegrating tablets (ODTs) with high friability are handled by soft-form tooling that reduces punch impact by 30 %.
High-Potency & Hormonal Products
Oncology tablets containing <10 µg API per dose are processed inside a split-butterfly valve isolator with glove-port access; validated cleaning to <1 µg/swab.
Hormone replacement patches (estradiol) use Alu-Alu cold-form foil with 100 % pin-hole camera inspection to guarantee zero light transmission.
Vaccines & Biologics
Lyophilized rabies vaccine vials (2 mL) are nested in 10-cavity thermoformed trays sealed with peelable Tyvek®; cycle validated down to ‑45 °C freeze-drying.
Single-dose pre-filled syringes (0.5 mL mRNA) are blistered in PETG forming web with desiccant cavity; residual moisture <0.5 % after 24 months at 25 °C/60 % RH.
Diagnostic & Point-of-Care Devices
COVID-19 antigen cassettes (3 mm thick) run on intermittent plate machines with 0.05 mm forming accuracy to protect delicate nitrocellulose membranes.
Blood-glucose test strips (50-count fan-fold) are sealed in high-barrier PVdC/PVC to maintain enzyme activity; vision system verifies printed lot number on every strip.
Medical Device Disposables
Safety lancets with 28 G needle are automatically fed by bowl feeder + star wheel at 200 pcs/min; blister cavity includes locking clip nest to prevent needle shift.
Insulin pen needles (4 mm, 32 G) are packed in 7-unit day-blisters with Alu-foil top web; peel force controlled between 4–6 N for geriatric compliance.
Veterinary & Pet Care
Heart-shaped deworming chews for dogs (2 g) use food-grade color masterbatch in PVC forming web; mold cavity engraved with logo for brand identity.
Aquaculture micro-pellets (2 mm, 0.8 g) are filled via multi-head weigher into 20-cavity blisters; desiccant canister inserted for tropical transport.
Nutraceutical & Probiotic Products
Gummy multivitamins (bear shape) are handled by soft-drop conveyor to avoid deformation; forming temperature kept at 55 °C to prevent vitamin degradation.
Freeze-dried probiotic tablets (50 B CFU) blistered under <5 % RH environment with inline moisture analyzer; shelf-life extended from 18 to 36 months.
Cosmetic & Personal Care Samples
Single-dose 1 mL serum capsules (retinol) use transparent Aclar® forming web for premium appearance; tamper-evident laser scoring added.
Sheet-mask sachets (25 g essence) are converted to 3-side-seal blister with easy-tear notch, replacing traditional pouches and reducing material use by 15 %.
Electronics & Battery Packaging
CR2032 coin cells packed in conductive PS trays to prevent short-circuit; surface resistivity <10⁴ Ω/sq.
Vape pods (2 × 2 mL) use child-resistant blister with push-through foil; validated to EN 14375.
Cold-Chain & Data Logging
Temperature loggers (TempTale® 4) are co-packed with vaccine blisters; RFID tag welded into cavity wall for seamless track-and-trace during ‑20 °C transport.
Dry-ice shipment kits include molded EPS insert with blister cavities for vials and phase-change material (PCM) bricks; validated for 120 h below ‑60 °C.
Every application above has been qualified on our machines with dedicated feeding systems, vision protocols, and validation dossiers (IQ/OQ/PQ) ready for regulatory submission.
