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Blister Packaging 101

Everything You Need to Know About Blister Packaging for Pharmaceutical Products

Blister packaging is a popular solution for manufacturers that want to keep individual pharmaceutical units sealed. By “popping” a blister, the user can retrieve a single unit of product, which often coincides with a recommended dose. 

In this guide, we’re going to cover all of the basics you need to know about blister packaging. We’re going to review key topics, such as: 

  • Is blister packaging the right medium for your product?
  • How are blister packs filled? 
  • How would a quality control team examine a filled blister pack? 

Why Use Blister Packaging? 

There are a variety of reasons that could influence a manufacturer’s decision to opt for blister packaging. Some key factors might include: 

Greater Quantity Control 

When filling containers in large volumes, blister packaging guarantees that only a certain amount of product is filled per container. This allows you to better forecast your production schedule and expected costs during the manufacturing process. 

Airtight Preservation 

As we know, different pharmaceutical products have different shelf lives. If the composition of a product is greatly affected by exposure to oxygen from opening and closing pill bottles, a blister package will ensure that individual units remain in an airtight, sealed environment until the moment the consumer is ready to take one. 

More Accurate Dosage 

Blister packs individually separate products. This means that manufacturers can more easily portion out dosages in a visual manner so that the consumer can more safely take their vitamins, supplements, or prescription medication. For example, if a prescription tablet only needs to be taken once daily for 16 days, you could fill a box with two 8-blister sheets for the consumer to extract their medication from. 

Less Product Movement 

The individual pockets in a blister sheet restrict the movement of the products inside far more effectively than a large pill bottle or another type of loose container. When transporting blister-packaged goods, their movement is reduced and thus also reduces the likelihood of damaged product in transit. 

Best Types of Pharmaceutical Products for Blister Packaging 

Depending on the hardness and texture of your products, blister packaging may work more effectively than other types of packaging. For example, capsule shells are often thin and brittle. They may break against the pressure the user exerts when opening the blister. Gummies may be too soft and sticky for them to effectively break through the barrier either. 

Typically, a harder softgel and or a tablet is the most effective medium for blister packaging. Their firmer outer textures prevent them from breaking when the user attempts to push them through the barrier that seals them inside. 

How Are Blister Packages Filled? 

Blister packages are filled using professional equipment designed just for this purpose. The size, volume capabilities, and features may vary depending on your needs. 

Typically, blister packages use a standard form-fill-seal process that is rather easy to implement. 

Forming 

The individual blister units are created on a sheet and size appropriately to the pharmaceutical unit that will be placed inside. Usually, the blister is made of plastic or foil. 

Filling 

After the blister containers are created, each pocket is filled with an individual pharmaceutical product from the batch that was created. As we mentioned above, most pharmaceuticals filled in a blister package are either firmer softgels or a tablet. 

Sealing 

After filling has been completed, the open blister sheets are then covered with the sealing layer. The sealing layer is usually made of tough paper-like material, lidding foil, or a combination of both. It should be easy enough to break through when the user applies pressure, but also sturdy enough to resist breakage when being transported or if it falls. 

Inspection and Quality Control 

Assuming the pharmaceutical products inside the blister package have been separately inspected for quality prior to filling, the packaging itself should also undergo a thorough review. During quality control for blister packaging, a specialist might inspect various components, such as: 

  • Does the sealing layer sufficiently cover the blister? 
  • Are all blisters filled, and with the correct product?
  • Is there only one individual unit per blister? 
  • Is the sealing layer too weak or too tough?
  • Are there enough blisters for the intended quantity? 
  • Are there any rips, tears, holes, or other signs of product-compromising damage? 

What is a Deblistering Machine? 

In addition to blister-filling solutions, deblistering equipment helps safely remove products from a blister package. These can be useful for reclaiming products from defective packaging to reduce the amount of product loss if any errors should arise in the production process. 

Get Better Blister Packaging for Your Operations 

At CapPlus, we invest countless hours in connecting pharmaceutical manufacturers with the most innovative products for their needs. If you are considering adding blister packaging to your capabilities or want to upgrade beyond your existing equipment, view our range of blister packaging machines or contact us anytime for more information.