The Ultimate Guide to Blister Packaging Machine

Blister packaging machines are critical equipment in the pharmaceutical and consumer goods industries.

In the field of manufacturing and packaging, blister packaging machines are vital equipment that play an important role in the efficiency and effectiveness of the production process.

These machines effectively seal the product in a clear plastic cavity, protecting it from external factors such as moisture, light and contamination. Blister packaging machines have become essential equipment in pharmaceutical, electronics, consumer goods and other industries.

In this comprehensive guide, we’ll take an in-depth look at how blister packaging machines work, their benefits, key features to look for when choosing a machine, and best practices for maintenance and operation.

The Ultimate Guide on Blister Packaging Machine

What is Blister Packaging?

Blister packaging is a transparent plastic film or sheet made into a blister. Methods such as heat pressing, bonding and other methods are used to seal the product in the cavity between the blister and the substrate. Blister packaging provides barrier protection that meets shelf-life requirements and a level of tamper resistance.

Blister packaging is commonly used for unit-dose medications such as tablets, capsules, ampoules, vials and syringes. It can also be used in small consumer goods, food and cosmetics.

Components of a Blister Packaging Machine

The main part of the blister packaging machine is the material-forming structure. The material is obtained from the feed frame, heated to the appropriate temperature, and then formed into the frame. This 18-part structure can be customized depending on material type and packaging requirements.

Additionally, the blister packaging machine will be able to pre-print material for the lid of each package. It will also have a printed positioning mechanism to help regulate where the sealing material sits within the blister cavity. It can also emboss sealed packaging if the manufacturer must do so.

Blister packaging machines create plastic containers by cold forming or thermoforming a roll of plastic wrap. They are used in pharmaceutical packaging. Aluminum foil is used to make blister cards on blister packaging machines. Foil and paper are commonly used to create push-fit packaging.

Blister packaging machines can also be used to provide cavities for plastic substances. By design, the thermoformed plastic cavity is strong enough to bear the weight of the product. The blister packaging machine is also capable of producing structural films that are easy to frame.

Types of Blister Packaging Machines

Depending on the working principle and structure, you can choose from the following types of blister packaging machines, including:

  1. Rotary Blister Packaging Machine: A high-speed machine that uses a rotating sealing system to create blister packs. It is usually used for mass production.
  2. Flat blister packaging machine: A machine that uses heat sealing technology to produce flat blister packaging. It is suitable for packaging smaller items and is often used in the pharmaceutical industry.
  3. Thermoforming blister packaging machine: This machine forms blisters by heating and shaping plastic sheets on a mold. It is commonly used in packaging food and consumer goods.
  4. Blister sealing machine: a semi-automatic or automatic machine that uses heat sealing or ultrasonic sealing technology to seal preformed blisters. It is used to seal blisters made by other machines.
  5. Skin packaging machine: A machine that uses heat and pressure to form a clear plastic film on a card or product on a tray. This type of packaging is often used to display products in a retail environment.
Types of Blister Packaging Machines

Benefits of Blister Packaging

Blister packaging offers an effective solution for businesses aiming to enhance product security, extend shelf life, and improve presentation while streamlining the packaging process and minimizing expenses. Key advantages of utilizing a blister packaging machine include:

A) Freshness

Separate compartments are available to organize items according to their specific uses, ensuring they are readily accessible when required by customers. Consequently, products such as medications, herbs, and other environmentally sensitive items are ideally suited for blister packaging to maintain their integrity and quality.

B) Good protection

Blister packaging is renowned for its excellent sealing capabilities, offering moisture resistance, rust prevention, and waterproof properties that significantly extend the preservation period of the contents.

C) Dose/Serving size

The packaging of pharmaceuticals and specific food products is designed to facilitate even distribution, ensuring that consumers utilize these items in appropriate quantities. Consequently, this method of packaging enhances the ease and safety of medication dosages for users.

D) Visibility

Containers featuring transparent plastic fronts enable customers to visually inspect the product prior to purchase. This design ensures that the contents are as advertised in terms of quantity and completeness. While these containers allow for visual verification, they restrict physical access, thereby safeguarding the product against tampering and theft.

E) Safety

Blister packaging offers an ideal solution for products requiring secure placement, as its design features individual compartments that prevent movement within the package. This effectively safeguards items from damage during transportation.

F) Customized

As is widely recognized, the process of thermoforming is employed in the creation of all plastic blisters. Consequently, each design is specifically tailored to accommodate the product it encases. This means that regardless of the size or number of items contained within a blister pack, it can be customized to fulfill the specific requirements of any product.

Disadvantages of Blister Packaging

Blister packaging is a popular choice for many products due to its ability to provide a secure and tamper-proof packaging solution. However, it is important to consider the disadvantages associated with this type of packaging.

One disadvantage of blister packaging is its lack of sustainability. Most blister packs are made of plastic and aluminum, making them difficult to recycle. This can lead to excessive waste and cause environmental problems.

Additionally, blister packs can be difficult for consumers to open. Hard plastic casings can be difficult to remove, especially for people with limited dexterity or strength. This can lead to frustration and potential injury when trying to access the product inside.

Blister packaging may not be the most cost-effective option for all products. The materials and processes involved in producing blister packaging can be more expensive than other packaging options, which can increase production costs and ultimately affect the overall pricing of the product.

Materials used in Blister Packaging

Materials used in Blister Packaging

Packaging film

The plastic film exhibits robust barrier capabilities against carbon dioxide, oxygen, and water vapor. It possesses high mechanical strength and exceptional transparency while maintaining resistance to breakage. These properties make it ideally suited for use in blister packaging applications.

At present, the most widely used pharmaceutical blister packaging material is PVC plastic sheet because of its good barrier properties against light, water vapor and odor of plastic sheets.

Base material

White cardboard, commonly utilized in blister packaging, is fabricated from bleached kraft wood pulp. Alternatively, it may be constructed using recycled cardboard which is then laminated with white paper on the foundational layer.

Coating materials

It is important to choose coating materials that are compatible with the substrate and blister packaging and to keep temperatures low during the sealing process to quickly seal without damaging the blister film. Soluble vinyl resin and water-resistant acrylic resin are ideal due to their clear appearance, high gloss, and efficient heat-sealing properties.

Specifications to Consider When Choosing a Blister Packing Machine

The following specifications should be considered when choosing a blister packaging machine.

Blister packaging machine productivity – The selection of a blister packaging machine should be based on its capacity to handle the required volume of packages within a specified timeframe. It is crucial to choose a machine that aligns with the output demands of your production system.

Speed – Select a machine equipped with an adjustable speed control for easy handling.

Dimensions – The specifications of the blister packaging machine encompass its dimensions and weight.

Power and air pressure requirements – Incorporate the energy consumption metrics of specific machinery essential for executing designated functions. It’s imperative to consider air pressure specifications, as they dictate the requisite force needed to achieve a complete seal on the material.

Material specifications – Explore machines designed to accommodate a variety of material types, tailored to meet diverse production requirements.

Level of automation – The degree of automation in blister packaging, whether manual or automatic, will be determined based on the associated costs.

How to Clean the Blister Packaging Machine?

When cleaning your blister packaging machine, it is essential to use a lint-free detergent solution. Ensure that the power and air supply are disconnected prior to initiating the cleaning process. Following this, employ a dry cloth to eliminate any remaining residues on the machine. Proceed by thoroughly cleansing components such as the hopper and bowl along with other parts of the machinery.

Before commencing the cleaning process for your blister packaging machine, it is imperative to thoroughly review the Standard Operating Procedures (SOPs) provided with your equipment. Depending on the specific model in use, there are several components that will require meticulous cleaning. Ensure all dust and debris are comprehensively removed from these parts. Any remaining components or scraps should be securely covered with plastic bags prior to their transfer to the designated general cleaning area.


Blister packaging machines are critical equipment in the pharmaceutical and consumer goods industries. Understanding the different types of blister packaging machines, their benefits, and best operating practices is critical to maximizing efficiency and productivity.

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