Automatic Vial Blister Packaging Machine

Absolutely. We strongly recommend and facilitate a No-Obligation Performance Validation Test at our state-of-the-art demo facility. You send us your specific vials (glass or plastic), blister forming film, and lidding foil. We will run a production-scale test on the machine, measuring key metrics like seal integrity, formation quality, and operational speed. You will receive a comprehensive Test Report with video evidence demonstrating how the HIGHNOW machine handles your exact products. This de-risks your investment and provides concrete data for your procurement committee.

Our support SLA is designed for maximum uptime and includes:

• Remote Diagnostics: 24/7 secure VPN access for our support engineers to perform real-time diagnostics.

• Spare Parts Commitment: We guarantee shipment of critical spare parts within 24 hours of order receipt, supported by a 98% parts availability rate.

• On-Site Support: A guaranteed response time of 48 hours for a certified engineer to be on-site for critical issues that cannot be resolved remotely.

• Preventive Maintenance Contracts: Tailored plans that include scheduled inspections, wear-part replacements, and system performance reviews to prevent unplanned downtime.

Seamless integration is a standard offering. The HIGHNOW machine is equipped with industry-standard Allen-Bradley or Siemens PLCs and communicates via EtherNet/IP and OPC UA protocols. We can design and supply custom intermediate conveyor systems and buffering solutions to synchronize with your upstream (filling machine) and downstream (cartoner) equipment. Prior to shipment, we conduct virtual and physical integration tests to ensure line synchronization, data exchange, and optimized material flow, creating a unified and highly efficient packaging line.

Vial integrity is paramount. Our machine utilizes a gentle, servo-driven pick-and-place system for transferring vials from the infeed conveyor into the blister pucks, eliminating the jarring impacts common in pneumatic systems. The transport pucks are precision-machined with V-shaped, soft-tip inserts to cradle the vial securely. Furthermore, the entire transport system uses cam-driven profiles for smooth acceleration and deceleration, preventing sudden movements. These features collectively reduce breakage rates to less than 0.1%, even for delicate glass vials, and minimize jam-related stoppages.

Our HIGHNOW Plant Data Management System is built for full regulatory compliance. The system features user access control with multi-level passwords, a complete and unalterable audit trail that records all operator actions and parameter changes, and electronic batch records. All data is stored in a secure SQL database with automatic backups. We provide IQ/OQ documentation packages that specifically validate the 21 CFR Part 11 functionality, including data integrity, security, and audit trail reviews, ensuring a smooth audit process for regulated markets.

Compliance and cleanability are foundational to our design. All product-contact surfaces are made from AISI 316L stainless steel with a #4 finish (Ra ≤ 0.8 µm), while non-product contact frames are AISI 304. The machine features a totally enclosed cabinet with IP55 rating for electrical components. It is designed for Clean-in-Place (CIP) with strategically located spray balls and quick-disconnect panels for easy access. All surfaces are sloped for positive drainage, and there are no crevices or dead legs where contaminants could accumulate. This design facilitates compliance with the most stringent GMP and FDA hygiene standards.

We have designed the HIGHNOW machine for exceptional operational agility. Changeover between different vial sizes is a tool-less and recipe-driven process. The operator simply selects the new vial size recipe from the Human-Machine Interface (HMI), which automatically adjusts servo positions. Physical changeover involves swapping out the modular puck assemblies and guide rails, which are color-coded and keyed for error-proofing. The total changeover time from one family of vials to another (e.g., 2ml to 10ml) is typically under 25 minutes, significantly reducing downtime in multi-product facilities. Each machine comes with a video-assisted changeover guide accessible via QR code on the machine.

Guaranteeing a hermetic seal is critical for product stability. The HIGHNOW machine employs a multi-zone, PID-controlled heated sealing station with temperature uniformity of ±1°C across the sealing platen. We combine this with a servo-controlled pressure application system to ensure consistent force. For validation beyond standard dye penetration tests, we offer an integrated High Voltage Leak Detection (HVLD) option. This non-destructive test can detect leaks as small as 5-10 microns. We provide full documentation and support for validation protocols per USP <1207> guidelines, ensuring your moisture-sensitive products are protected and your regulatory submission is robust.

Our blister packaging machines achieve speeds of 30-40 cycles/minute, depending on product type and blister design complexity.

We offer a standard 12-month warranty covering parts and manufacturing defects, extendable based on agreement.

We offer EXW, FOB, or CIF shipping terms and support with documentation for smooth customs clearance.

HIGHNOW provides comprehensive pre-sales support, including on-site facility assessments, production layout planning, and tailored equipment recommendations based on client requirements (e.g., output, stability). We also share technical parameters and arrange visits to existing client sites for verification.

HIGHNOW provides blister packaging solutions for pharmaceuticals, pet care, food supplements, and cosmetics, supporting vials, ampoules, cartridges, and irregular containers.

Absolutely. We customize feeding systems, molding plates, and sealing tools to accommodate standard and irregular vial types like syringes, ampoules, and cartridges.

We offer optional integrated vision inspection for detecting missing products, defects, incorrect labeling, and compliance tracking (e.g., UDI).