>>The Next Step: Product Handling in Blister Packaging
We have already taken a look at the role of blister packaging in healthcare. While not historically dominant in the medical device space, blister packaging has gained traction thanks to its ability to deliver single-use sterility, tamper evidence, and visual clarity.
Previously covered in Forming Blisters for Medical Device Packaging:
- The range of primary packaging formats—pouches, trays, wraps, and blisters.
- Why blister packs are ideal for syringes, surgical kits, nasal atomizers, and other medical devices.
- How forming methods like plug assist and cold form accommodate deeper cavities and complex geometries.
- Material selection for sterilization compatibility.
You can take a look at the previous article, “Forming Blisters for Medical Device Packaging” for an introduction to blister packaging for medical devices.
Now Loading: Product Handling in Blister Packaging
Once the blister cavity is formed, the next logical step in the process is getting the medical product into the blister package. This step, product handling or feeding, represents an operational phase where precision and process control directly impact packaging efficiency and product integrity. Blister packaging machines can form, seal, and cut at high speeds, but loading can be a bottleneck, particularly if you are hand-loading product.
Medical devices vary in size, shape, fragility, and orientation. Feeding a prefilled syringe or a wearable pump into a blister cavity is not just about speed. It requires controlled movements and precision, given the blister cavity shape and size tolerance. Misfeeds can lead to lower package output, damaged products, compromised sterility, and costly rejects. In production environments, even minor inconsistencies can ripple into major inefficiencies and consequences.
Feeding medical devices also differs significantly from solid dose packaging. While tablets and capsules are typically uniform in shape and size, medical devices often consist of multi-component assemblies that may require preassembly or staging prior to entering the blister machine. These assemblies can include diagnostic kits, surgical tools, or wearable systems with multiple parts, each requiring precise orientation and handling. This complexity demands a more tailored and flexible feeding approach.
Whether packaging diagnostic strips, surgical tools, or multi-component kits, the feeding method must be tailored to the product and the process. That might lead you to think many medical device feeding solutions are custom, and while many are, there are also common methods used across the industry.
Containment and Sterility in Blister Packaging
During feeding, containment protocols become particularly important. Whether using manual, semi-automatic, or automated systems, feeding equipment must operate within cleanroom standards and be designed for easy cleaning and minimal particle generation.
Key sterility and containment features for feeders include:
- Cleanroom-compatible construction materials such as stainless steel.
- HEPA-filtered enclosures to maintain sterile airflow around the feeding zone.
- Modular designs that isolate the feeding area from other packaging operations.
- Surfaces engineered for easy cleaning and reduced contamination risk.
- Interchangeable change parts and tooling if running multiple products.
- Integration with UV sterilization or other microbial control technologies
- Ventilation systems that minimize particle generation during device handling
Feeding Methods for Medical Device Blister Packaging
Feeding medical devices into blister cavities requires a range of automation strategies, each suited to various products and production volumes. Here are some of the most common methods used in the industry:
- Pick-and-place systems: Ideal for high-speed applications, these systems use a simple pick and place motion to transfer devices from a staging area into blister cavities with precision and repeatability.
- Robotic arms: Flexible and programmable, robotic feeders can handle complex motions, shapes, and product orientations. They are especially useful for delicate, irregularly shaped devices, or products that are not pre-oriented.
- Vibratory bowl feeders: These systems use vibration to orient and feed small components like ampoules. They are compact and efficient for high-volume, small-part packaging.
- Tray-based loading: For multi-component kits or larger devices, tray-based systems allow for manual or semi-automated loading from pre-arranged trays. Trays can be used to present product to pick and place or robotic feeders for placement into blister packages.
- Custom feeders: Feeding equipment customized to specific product and blister packaging applications, may utilize a combination of conveyors, trays, smart cameras and vision technology, pick and place systems, and robotic arms.
Selecting the right feeding method depends on the product’s physical characteristics, required throughput, and packaging environment. A well-matched feeding system ensures consistent placement, minimizes rejects, and supports overall production efficiency.
Pharmaworks Feeding Technology in Blister Packaging
Pharmaworks, a leader in blister packaging innovation, offers a range of feeding technologies that enhance both performance and flexibility in medical device packaging. Pharmaworks blister machine platforms support scalable automation, allowing manufacturers to start with manual or semi-automated systems and upgrade to fully automated lines as production needs grow.
Pharmaworks feeding solutions include advanced systems tailored for medical devices, such as:
- FA1 and FA3 Pick and Place Feeders for high-speed, precision placement of regularly shaped devices.
- Robotic Feeders for flexible handling of complex motion, shapes, and orientations.
- Tray Loaders for multi-component kits and larger assemblies that are prearranged in preparation for the desired picking method.
- Infeed Conveyors for controlled product transport or orientation prior to blister loading. Includes vibratory, indexed, and puck-based systems tailored to device geometry.
- Custom Feeders designed for complex product geometries and unique blister formats.
Feeder Integration of Solutions Provided by Other Popular OEMs
Pharmaworks also supports integration of third-party feeding technologies, enabling manufacturers to build flexible, high-performance blister packaging lines.
These systems combine smart sensors, vision technology, and Ethernet-based communication protocols to ensure accurate orientation, synchronized operation, and real-time fault detection. It could also be as simple as shared discrete I/O signals between the feeder and blister machine to make integration more plug and play.
Feeder control GUIs can also be hosted directly on the blister machine’s HMI, giving operators centralized access to settings, diagnostics, and adjustments without jumping between multiple touchscreens.
| Feeder | Recommended Blister Machine | Recommended Product Types | Reommended Product Size | Recommended Industries |
|---|---|---|---|---|
| FR1 Robotic Feeder Combination of an indexed puck conveyor and robotic arm | TF1, TF1e, TF1pro Small to Medium format/index 3rd Party blister machines | Solid Dose, Devices | Any up to max blister machine format size | Pharmaceutical, Nutraceutical, Animal Health, Consumer, Medical |
| SE Feeder Combination of vibratory conveyor, flat belt conveyor, and servo driven pick and place feeder | TF2, TF3 Medium to Large format/index 3rd Party blister machines | Solid Dose, Tablets, Capsules, Gelcaps, Small Similarly Shaped Devices | Small – Medium | Pharmaceutical, Nutraceutical, Animal Health, Consumer, Medical |
| Custom Feeder Combination of popular and innovative technology designed specifically for application | Any | All | Any up to max blister machine format size | Medical, Pharmaceutical, Nutraceutical, Animal Health, Consumer |
| 3rd Party Feeder Any feeder interfacing through ethernet or discrete signals | Any | Customers Choice | Any up to max blister machine format size | Medical, Pharmaceutical, Nutraceutical, Animal Health, Consumer |
| Manual Feed Tray Basic tray for use with manual feeding by operators | TF1, TF1e, TF1pro, TF2, TF3 Any Third-Party Blister Machine | Any | Any up to max blister machine format size | Pharmaceutical, Nutraceutical, Animal Health, Consumer, Medical |
| FA3 Pick & Place Feeder A servo-driven pick and place feeder sized to fill multiple blister indexes per machine cycle maximizing output | TF2, TF3 Medium to Large format/index 3rd Party blister machines | Solid Dose, Tablets, Capsules, Gelcaps, Small Similarly Shaped Devices | Small Typical tablets and capsule sizes | Pharmaceutical, Nutraceutical, Animal Health, Consumer, Medical |
| FA1 Pick & Place Feeder A servo-driven pick and place feeder sized to fill single or smaller number of blister indexes per machine cycle | TF1, TF1e, TF1pro Small format/index 3rd Party blister machines | Solid Dose, Tablets, Capsules, Gelcaps, Small Similarly Shaped Devices | Small Typical tablets and capsule sizes | Pharmaceutical, Nutraceutical, Animal Health, Consumer, Medical |
Blister Packaging Machines for Medical Device Packaging
Pharmaworks equipment is built with cleanroom compatibility in mind, featuring stainless steel construction, HEPA-filtered enclosures, and easy-to-clean surfaces just to name a few. Pharmaworks product handling technology is designed to minimize particle generation and support aseptic conditions.
By focusing on feeding innovation, Pharmaworks helps manufacturers improve throughput, reduce rejects, and maintain sterility, all of which are key factors in successful medical device blister packaging.
Next in this Medical Device Blister Packaging Series
As we have seen, feeding is a critical step in the blister packaging process and is one that demands precision, sterility, and flexibility. It is still just one part of a broader packaging process though.
In upcoming articles, we will explore inspection systems and downstream automation that complete the blister packaging line. Stay tuned as we continue to unpack the full lifecycle of blister packaging for medical devices—from forming to final delivery.
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