소개
A blister packing machine can look “easy” on paper: feeding the base film, forming the cavities, filling the product, sealing with the lidding foil, coding, and finally cutting the blisters. But stable blister output depends on small details staying under control—forming consistency, web tracking, sealing stability, and the way the machine behaves after a format change.
This guide keeps the logic simple. You’ll learn what the equipment does, how the process works step by step, what the common “types” really mean, and the 9 features that change day-to-day results. You’ll also see what drives cost (without getting lost in numbers), and a clear way to choose a setup that fits your product, your team, and your production rhythm.
What is a blister packing machine?
A 블리스터 포장기 forms cavities in a base material (PVC/Alu/PET), loads products into those cavities, seals a lidding material over the top(Alu/Paper), and then cuts the web into the final pack format (sheets). Many lines also add coding and visual inspection function (such as Basler visual inspection) along the way, so defects are removed before downstream packing.
You’ll also hear the terms blister packaging machine, blister pack machine and blister sealing machine used in the same way. In most buyer conversations, they refer to the same core function: forming, feeding, sealing, and cutting—repeated reliably, shift after shift.
What is a blister pack? (Quick definition)
A blister pack is the finished unit-dose package format: a product is sealed between a formed cavity (the “blister”) and a lidding layer (often foil). The cavity is typically made from a thermoformable film (common structures include PVC-based films, sometimes with barrier coatings or laminations), while the lidding layer is often aluminum foil with a heat-seal coating that bonds to the cavity flange.
Two packaging routes dominate. 열성형 shapes a heated plastic film into pockets and is widely used for its efficiency and product visibility. Cold forming (often called Alu-Alu) mechanically forms an aluminum-based laminate into pockets and is chosen when you need very high barrier protection (moisture/oxygen/light), accepting the trade-offs of lower visibility. This is why the “right” blister format is not just a packaging decision—it directly determines the machine type and the performance window you can expect. To gain a deeper understanding of the blister packaging, please refer to this article: What Is a Blister Pack
How does a blister packing machine work?
Most lines can be understood through five stages. When output or quality drifts, the root cause usually lives in one of these steps.
Step 1: Forming (creating the cavities)
The base web is fed into a forming station. In thermoforming, heat softens the film and tooling shapes it into cavities with vacuum and/or pressure. In cold forming, tooling draws aluminum laminate into cavities without the same heating behavior, and the geometry and material limits become more sensitive.
Step 2: Feeding / loading (placing the product)
The product is placed into each cavity using a feeding system matched to the product shape and fragility (tablets, capsules, or other units). The goal is not only “no missing pieces,” but also minimal breakage and minimal dust.
Common failure pattern: powder dust or fragments build up on sealing surfaces, turning a feeding issue into a sealing issue.
Step 3: Sealing
Lidding material is introduced and bonded to the cavity flange using controlled heat and pressure. Consistency matters more than headline temperature. If the web tracking or registration is unstable, the seal may land off the flange even when settings look “correct.”
Common failure pattern: leaks or weak seals from unstable energy/pressure, misalignment, or contamination.
Step 4: Cutting / perforation / discharge (making the final pack)
The sealed web is cut into blister sheets. Perforation may be added for tear-off convenience. Discharge must be stable so packs don’t jam, scuff, or deform.
Common failure pattern: burrs, poor perforation quality, or mechanical jams that create stop-start instability.
Step 5: Inspection & rejection (optional but common)
Some lines add inspection for missing product, coding issues, or visual defects, rejecting bad packs automatically. This can reduce downstream waste and help stabilize quality—if it’s integrated and tuned correctly.
Types of blister packing machines
Most “type lists” get long. What matters is the grouping that changes packaging capability, stability, and operating cost.
By forming method: thermoforming vs cold forming
Thermoforming (often used for Alu-PVC packs) is common for efficiency, visibility, and broad applications. Cold forming (Alu-Alu) is chosen when barrier performance is the priority and the product demands it.
By structure & motion: roller vs flat-plate (and hybrids)
Roller type blister packaging machines use roller-based sealing and are often associated with higher-speed continuous motion. Flat-plate machines use plate tooling and are often chosen for cavity flexibility, precise control, and practical format-change realities—especially where setups change frequently. Hybrids try to balance the two.
By automation level: manual, semi-automatic, fully automatic
Manual or semi-automatic configurations can make sense for small volumes, frequent changeovers, or environments where operator control is part of the workflow. Fully automatic systems are the norm for commercial, sustained output and repeatable quality—especially when upstream/downstream integration is planned.
Table: quick way to think about “types”
| 유형 | Best fit | Trade-offs |
| Thermoforming (Alu-PVC) | High efficiency, visibility, broad use | Barrier depends on film structure |
| Cold forming (Alu-Alu) | Maximum barrier for sensitive products | Lower visibility, typically lower speed, higher material/tooling cost |
| Roller type | Throughput-focused, continuous motion | Tighter control needs; changeovers can be more involved |
| Flat-plate type | Flexible formats, controllable forming/sealing | Often lower peak speed than roller designs |
| Fully automatic line | Stable output with less manual variation | Higher complexity; integration and training matter |
The 9 must-know features (what they change in real production)
These features matter because they determine whether the line stays stable when conditions change: different products, different shifts, different materials, and actual downtime.
1) Real output vs rated speed
Rated speed is a ceiling, not a guarantee. Real output depends on by the material used, the blister size, how often the line stops, how much scrap is created during startup and after changes, and how stable the sealing and tracking remain across a full shift. A slower machine that runs steadily can produce more sellable packs per day than a faster machine that needs constant intervention.
2) Material fit (forming web + lidding)
“Compatible” doesn’t always mean “stable.” Material fit is about whether the machine can form consistent cavities and seal reliably across your real film range, foil type, and ambient conditions. If the process window is narrow, small variability in material batches can turn into defects and downtime.
3) Forming quality (depth, uniformity, thinning risk)
Forming quality affects everything. Deep pockets and sharp geometry increase stress and thinning at corners, which can cause cracks or cosmetic distortion. If cavities aren’t uniform across the web, feeding reliability drops and sealing becomes inconsistent. Good forming control makes the whole line easier to run.
4) Sealing stability (consistent bonding, not just “temperature”)
Sealing isn’t a single knob. Stable sealing depends on repeatable heat delivery, uniform pressure, clean sealing surfaces, and correct registration so the seal lands on the flange. A common mistake is pushing temperature higher to “fix leaks,” which can mask the real cause (misalignment, contamination, or unstable web handling) and introduce new problems like distortion or foil damage.
5) Web handling & registration (tension, tracking, alignment)
Web handling is the silent driver of quality. When tension and tracking drift, you see symptoms like wrinkles, print misalignment, and seals landing off-center. Even the best sealing station cannot compensate for a web that wanders. If you want consistent packs, prioritize stable tracking and repeatable registration behavior.
6) Feeding accuracy & gentle handling (missing, breakage, dust)
Feeding issues rarely stay “just feeding.” Broken tablets, chipped edges, and dust buildup create contamination that travels into sealing. Missing units create rejects, and those rejects create stop-start behavior that destabilizes heat and web control. Feeding should be matched to the most difficult product, not the easiest one.
7) Changeover & cleaning design (repeatability and access)
Changeover is more than swapping tooling. It’s also cleaning, threading, sensor checks, and the time it takes to return to stable packs. A design that is easy to access and repeatably set up reduces operator variability and makes the line predictable. Also watch for dust traps—places where powder and fragments collect and later cause sealing defects.
8) Inspection & rejection readiness (when it matters)
Not every line needs full vision inspection on day one, but many lines benefit from planning for it. Inspection reduces the cost of defects by catching problems early. If you plan to add inspection later, readiness matters: physical mounting, integration, and reject handling should be feasible without a full redesign.
9) Documentation & compliance readiness (a practical mindset)
Even outside strict pharma, good documentation shortens commissioning time and improves repeatability after maintenance. The practical question is whether the supplier supports stable operation over the equipment lifecycle—clear setup guidance, repeatable settings, and structured support for acceptance testing and training.
A brief, non-sales example: many manufacturerssuch as Uhlmann, Romaco, and 루이다패킹, position blister solutions as part of a line—blistering plus downstream cartoning—because stable integration often matters as much as the blister station itself.
Advantages and disadvantages of blister packaging
Blister packaging remains popular because it protects products, offers tamper evidence, and provides a clean unit-dose format that supports handling and distribution. It can also improve product presentation and reduce cross-contact between doses.
The downsides are real too. Material sustainability and recycling can be complicated depending on structures used. Equipment investment is meaningful, and sealing failures can be “silent” (packs may look okay but underperform in barrier or peel behavior). That’s why the earlier sections focus on sealing stability and web control rather than only speed.
How to choose the right blister packing machine
Start with your package goal. If barrier performance is critical, that usually pushes you toward cold forming blister machine (Alu-Alu blister machine). If cost and visibility are the priority and barrier needs are moderate, thermoforming (Alu-PVC blister machine) is often the practical route.
Next, match the structure to your operating reality. If your format changes are frequent, don’t underestimate flat-plate practicality and changeover friendliness. If sustained throughput is the priority and your format is stable, roller/continuous designs may fit better.
Then test your “hardest products” conceptually: the most brittle tablet, the dustiest product, the most awkward shape, or the most demanding cavity. If the system can run that product reliably, everything else becomes easier.
Finally, think in line terms. If your plan includes cartoning, evaluate blister-to-cartoner handoff early so your line doesn’t bottleneck later.
Installation, maintenance, and line integration
Stable blistering depends on stable setup. Good routines focus on cleanliness around feeding and sealing zones, consistent warm-up behavior, and periodic checks for alignment, wear, and tracking stability. Many “quality problems” are really setup drift problems.
For integration, blister-to-cartoner flow is one of the most common upgrades. The key is stable transfer and matched rhythm so blister output doesn’t pile up or starve the cartoner. If you’re planning a complete line, it’s worth considering blistering machine and 카토닝 머신 together rather than as isolated machines.
자주 묻는 질문
1) When do I need a Alu-Alu blister machine instead of a Alu-PVC blister machine?
When barrier performance is a primary requirement for product stability or distribution conditions. Expect trade-offs in visibility.
2) Roller type blister machine vs flat-plate blister machine—what’s the practical difference?
Roller types often target higher-speed continuous motion. Flat-plate types often emphasize controllable forming/sealing and practical format flexibility. The better choice depends on your product variety and operating rhythm.
3) Why do leaks happen even when temperature looks correct?
Because sealing stability depends on pressure uniformity, clean surfaces, correct registration, and stable web handling—not temperature alone.
4) Do I need vision inspection?
Not always immediately. It becomes valuable when missing product, print/coding, or subtle defects create downstream waste or compliance risk. Planning for future integration is often smart.
5) Why is changeover so important if my machine is “fast”?
Because changeover affects effective capacity—how many sellable packs you produce per week—especially in multi-product operations.
참조
FDA Process Validation (PDF):
https://www.fda.gov/files/drugs/published/Process-Validation–General-Principles-and-Practices.pdf
ISPE Baseline Guide Vol 5 (C&Q 2nd Edition):
ASTM F88/F88M (Seal Strength standard page):
