Multi-Bottle Blister Packaging | Mixed Container Line

Bottle Type Application

Vial

Ampoule

Cartridge

Oral Liquid Bottle

Prefilled Syringe

Special-Shaped Bottle

Bottle type combination

Blister Packaging Solutions for Bottle Type Combination

Our line revolutionizes combination packaging by enabling different container types—such as a vial, ampoule, and syringe—to be securely packaged together within a single blister cavity. Intelligent vision systems and customizable nesting ensure precise positioning for complex combination therapies or tailored kit packaging, offering unparalleled flexibility and expanding your product possibilities.

Select the Appropriate Blister Lines for Your Product

With 20 years' experience, we offer professional small-bottle blister packaging production lines, including for irregularly shaped bottles and multilingual leaflets,adapting fast to industry rules.

Differences Between HIGHNOW Vial Blister Packaging Lines and Traditional Models

Traditional Mechanical Structure

Servo motor

Other brands

Material replacement by stopping the machine

Mechanical

Position each station manually after replacing the mould

One traction station

None

Mechanical type

14 to 15 pushers

No self-lubrication function

Cylinder control

Other brand bearings

Stainless steel

Motor

Control system

Replacement materials

Forming

Mold replacement and adjustment

Traction station

Feeder

Transfer station

Push device

Lubrication function

Carton automatic feeding device

Pneumatic components

Lid

HIGHNOW's Vial Blister Production Line Structure

+25 servo motors

SCADA network software: 1500 series PLC, Siemens touch screen

Production doesn't need to stop thanks to intelligent material switching.

Blisters are sturdy and full, positive pressure blowing, concave molding

Position each station manually after replacing the mould

Equipped with two traction stations and two servo motors

Vibration feeder with adjustable track

Using robots for quick and smooth operation

22 sets of pusher heads

Features a self-lubricating system

Servo control

Festo bearings, chains: German BKD brand

Hard anodized aluminum profiles

Your Trusted Partner for Vial Blister Packing

We work worldwide, delivering numerous benchmark projects across industries. Success is down to relentless pursuit of excellence in technology, quality, and service.

Saudi Arabia

Optimization plan for mold head debugging of Blister Lines for Vial Product

Russia

optimization plan of blister lines for ampoule product

Georgia

optimization plan of blister lines for ampoule+vial product

Indonesia

optimization plan of blister lines for syringe product

FAQ

Unlock Industry-Specific Packaging Solutions! Discover how HIGHNOW addresses unique challenges in pharmaceutical, pet food, food & cosmetics industries. From GMP compliance to moisture-proof barriers, our FAQs reveal specialized machines that boost efficiency 40%+, ensure zero contamination, and handle diverse materials. Click to explore tailored solutions for your industry!

What is the maximum number of different container types that can be packaged within a single blister cavity, and how is positioning accuracy maintained?

Our combination blister line can handle up to 4 different container types simultaneously within a single cavity, maintaining positioning accuracy of ±0.3mm for each component. This is achieved through individual servo-controlled placement systems and real-time vision verification using 6MP cameras at each station. Validation data from 500+ combinations shows Cpk ≥1.67 for all container positioning parameters.

How do you prevent cross-contamination between different drug products in combination packaging?

We implement modular isolation technology with physical separators and dedicated handling tools for each container type. The system features validated cleaning protocols between product changeovers, demonstrating residue levels <0.08 μg/cm² per EMA guidelines. Material compatibility studies ensure no interaction between different container materials during packaging and storage.

What is the production speed for combination blister packaging compared to standard single-container lines?

Our combination lines achieve 80-100 blisters per minute, depending on complexity, with OEE ≥85%. While moderately slower than single-container lines, this represents ≥300% efficiency improvement versus manual kit assembly. The system maintains synchronization accuracy of ±0.1 seconds between all placement stations to ensure continuous flow.

How quickly can production change between different combination configurations?

Our recipe-driven changeover system enables complete combination transitions in ≤20 minutes using pre-configured tooling sets and automated parameter recall. The system stores 150+ combination recipes with auto-calibration of all vision and handling systems, achieving ±0.4mm repeatability across change cycles.

What vision inspection methodology ensures 100% component presence and correct orientation in combination blisters?

We employ multi-station vision inspection with 8-12 MP cameras performing sequential checks at each placement station. The system verifies: component presence (99.99% accuracy), correct orientation (99.97% accuracy), and proper nesting in custom cavities. AI-based algorithms adapt to different container shapes with false rejection rate ≤0.008%.

How does the system handle containers with significantly different heights and diameters in the same blister?

Our adaptive cavity design accommodates height variations up to 45mm and diameter differences up to 25mm within the same blister. Customizable divider systems and segmented forming technology ensure secure nesting for all container sizes, with validated stability testing showing resistance to 5G vibration forces during transport.

What is the total cost comparison between combination blister packaging and traditional separate packaging with secondary assembly?

Our TCO analysis shows 35-40% cost reduction versus separate packaging plus manual kit assembly, achieved through: elimination of secondary packaging (60% reduction), labor savings (75% reduction), and inventory optimization (30% reduction). Typical ROI period is 18-22 months for moderate-volume combination products.

What regulatory documentation supports combination product packaging for global submissions?

We provide complete validation packages including: Container-Closure Integrity Testing for combination configurations, Compatibility Studies between different containers, Stability Data for multi-component systems, and Human Factors Validation for patient use. All documentation meets FDA Combination Product requirements and EMA guidelines for fixed-dose combinations.

How sustainable are combination blister solutions compared to traditional multi-package systems?

Combination packaging reduces total material usage by 45-60% versus separate packaging, with carbon footprint reduction of 50-65%. We offer recyclable mono-material blisters and optimized cavity designs that minimize material waste while maintaining shelf life equivalent to individual packaging for all components.

What technical support ensures successful implementation of combination packaging lines?

Our dedicated combination packaging team provides 72-hour installation supervision, 40 hours of operator training, and 24/7 remote monitoring. We guarantee ≤4-hour response time for technical issues and maintain combination-specific spare parts with ≤18-hour delivery. Customer data shows ≥98.5% uptime and 100% regulatory compliance for combination products.

From demand analysis to equipment delivery, we provide full-process service support:

24/7 online technical consultation, with a fault diagnosis rate of over 95%.

Provide on-site operation, maintenance, and GMP compliance training.

Global spare parts inventory network, rapid response within 72 hours.

Solutions for hardware and software upgrades based on production capacity requirements.

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