Alu Alu Blister Packing Machine

Blister Packing Machine (Alu-Alu )

Automatic Blister Packing Machine design of the machine is ergonomic and used for both the Cold Forming (ALU/ALU) and Thermo Forming (PVC/ALU) blister packs. This machine is suitable for Large production batches in the pharmaceutical industry. The main movements are mechanical and pneumatic, and all the control systems used in the equipment are the best in the electronic market.


The core structure of the machine, constructed from mild steel, features SS 304 frames that are welded and secured to a sturdy framework. This framework supports various modular stations arranged in a balcony-like design. Inside the machine, all the necessary drive components and extensive wiring are positioned. The operation of the machine’s stations is managed by a central spline shaft, powered by the main motor. The machine is equipped with two servo motors for the control of the Indexing and Feeding systems. The Feeding process is performed by a Product Transfer Roller (PTR) for precise handling of Alu/Alu Blister. The entire setup is placed on six adjustable studs, allowing for easy cleaning of the area beneath the machine. Safety measures are in place to protect the operator. Access to the adjustments of the cantilevered modular stations is from the front of the machine. The process of mounting and dismounting the format parts is straightforward, requiring minimal tools and effort. It is possible to complete a full set of changeovers in less than 30 minutes, minimizing operator fatigue.

Main Features:

  • Packing Speed: 30 Cycle/min for Thermo-Forming, 30 Cycle/min for Cold-Forming
  • Feeding System: Auto feeding system by PLC Logic with pneumatic Combination. (For critical products)
  • Servo Drive Indexing: Servo web indexing by rigid PLC Logic.
  • Operator Interface: User-friendly MMI touch screen (Man-machine interface)
  • Pneumatic Operations: Festo makes for fast response, oil-free, minimum wear and tear, easy maintenance, and universal Availability of bought-outs.

Table of Contents

  • General
  • Salient Features
  • Operational Requirements
  • Utilities
  • Maintenance
  • Commissioning and Documentation
  • Training
  • Packaging
  • Deviations
  • Delivery

Equipment contains

  • Base film-loading station.
  • Pre-forming base film platen heating station.
  • Cold forming station.
  • Feeding systems which are product, layout, or base foil dependent.
  • Web transport station.
  • Sealing Station for sealing of the base film to the lidding film.
  • Embossing on the sealing station.
  • Film indexing station.
  • Punching station.
  • Trim winding assembly.

Field Identification

This system is used for small consumer goods, foods, and pharmaceuticalstThe primary component of a blister pack is a cavity or pocket made from a formable web, usually a thermoformed plastic. This usually has a backing of paperboard or a lidding seal of aluminum foil or plastic. Blister packs are useful for protecting products against external factors, such as humidity and contamination for extended periods. Opaque blisters also protect light-sensitive products against UV rays.

Allocated floor space for the equipment is with a clear ceiling height of 3 Mts. Approx.

To be installed in 4.5×4.5 Mts. Area.

(i)       Room Temperature NMT 27 degrees C

(ii)     RH 45-55%

(iii) Non-flame proof area

Salient Features / General

  1. Unit to be compact with ease of operation.
  2. Ease of maintenance
  3. Easily cleanable
  4. All gaskets provided to avoid leakages should be amenable for easy removal and re-fixing,
  5. All electrical/pneumatic parts should be pre-wired.
  6. Complete safety interlock design
  7. All bolts, and nuts on the exterior part of equipment are to be preferably with cap head or cap nut.
  8. Parts which are required for cleaning should be provided with quick fixing arrangement

Material of Construction – The equipment body should be SS 304, SS 316 L.

Electrical Construction –  Non flameproof

Operational requirements

Capacity: Max. Speed – 50 cycles / Minutes
  • Max Forming Area -140X220 MM
  • Min Pack Size – 30x60MM
  • Optimum Forming Depth –18MM
  • Max Reel Diameter – 440 MM
  • Max Lidding Foil – 226 MM
  • Max Core Diameter -70 to 76 MM
Control Parameter –

The system shall operate with a minimum of operator involvement. Operation shall be safe from an operator and environmental standpoint. The system shall be operated locally at the equipment itself

Functional Requirements
  • Connected Load (Kw) – 15 KW
  • Average Power Consumption – 5 KW
  • (Approx.) Supply 3 Phase, 4W+E – 4 Wire + Protective Earth-in
  • Cooling Water Consumption –120 – 150 Ltr/Hr
  • Compressed Air – 16 CFM
  • Machine’s Dimensions- Approx. in mm
  • Machine Width: 1200
  • Machine Height : 2000
  • Machine Length : 4000
Power failure/recovery

In the event of a power failure, the system shall protect the product against damage. The system will stop in a safe mode automatically upon loss of electricity, air, or other major utility and will require operator intervention to re-start

Depending upon the options chosen in the overview section, the system will:

i. Manually restart based on operator inputs (operator initiates power recovery sequence).


To provide utilities at ONE POINT is the user’s responsibility. Supplier to give details and drawings for the exact size, location, type, capacity, etc. of the utilities required.


The supplier should provide (at minimum) the following maintenance instructions,

  • Maintenance and operation manuals along with as-built drawings
  • Lubrication instructions
  • Daily checks on the machine
  • Cleaning procedures

Commissioning and Documentation

  • The Supplier will submit a DQ (Design Qualification) document.
  • IQ/OQ/PQ to be completed by the supplier along with Company representatives.
  • The Supplier is to demonstrate the Performance of the machine at the site as per agreed terms.
  • The Supplier is to submit the following certificates:
  • MOC Certificates.
  • Calibration certificates of all the instruments used having traceability to NPL / NIST
  • Performance certificates of Tests conducted
  • At the manufacturers/Supplier end for Motors / Gear Box / Fan and other critical bought-out items with Serial nos.


The Supplier shall provide a Project Manager for the project to provide a single communication point with the User.


Start up support: Supplier to train the respective technical associates on operation, maintenance, and cleaning of the equipment wherever applicable
Post-start-up support :

Telephone / Fax / E-mail ID / Address

Replacement parts availability list (normal lead times shall be listed).

System improvements (supplier shall notify the user of any improvements.

Packaging: Supplier to specify packaging of machine for safe transportation and delivery at the site

Deviations: Any deviation from URS shall be highlighted.

Delivery: As per purchase order. To be delivered at :

Company Address

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About Pharmaceutical Guidanace

Ms. Abha Maurya is the Author and founder of pharmaceutical guidance, he is a pharmaceutical Professional from India having more than 18 years of rich experience in pharmaceutical field. During his career, he work in quality assurance department with multinational company’s i.e Zydus Cadila Ltd, Unichem Laboratories Ltd, Indoco remedies Ltd, Panacea Biotec Ltd, Nectar life Science Ltd. During his experience, he face may regulatory Audit i.e. USFDA, MHRA, ANVISA, MCC, TGA, EU –GMP, WHO –Geneva, ISO 9001-2008 and many ROW Regularities Audit i.e.Uganda,Kenya, Tanzania, Zimbabwe. He is currently leading a regulatory pharmaceutical company as a head Quality. You can join him by Email, Facebook, Google+, Twitter and YouTube

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