Prefilled Syringe Blister Packaging | Tamper-Evident & Secure

Bottle Type Application

Vial

Ampoule

Cartridge

Oral Liquid Bottle

Prefilled Syringe

Special-Shaped Bottle

Bottle type combination

Blister Packaging Solutions for Prefilled Syringe

Designed to meet strict sterility requirements, our syringes blister packaging incorporates specialized carriers and vision-assisted alignment. Servo control ensures gentle handling and accurate placement, providing a foolproof solution for pre-filled syringes.

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.

PBL-400SZ

High-speed Automatic Production Line for syringe/Ampoule/Vial/Oral Liquid/Cartridge

Punching frequency:
16-35 times / minute 1-12 plates / time
Boxing capacity:
200-350 boxes / min

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 production speed for prefilled syringe blister packaging while ensuring tamper-evident integrity?

Our prefilled syringe blister packaging line achieves ≥140 blisters per minute (equivalent to 280 syringes/minute) while maintaining tamper-evident integrity with 100% verification. Validated through 21-day continuous GMP runs, the system demonstrates: mechanical precision (positioning accuracy ±0.25mm), seal strength ≥40 N/25mm (ASTM F88), and rejection rate ≤0.004%. All critical parameters show Cpk ≥1.67 across 8 million syringe validation runs.

How do you prevent plunger movement and silicone layer disruption during high-speed packaging?

We implement acceleration-controlled handling limiting forces to <1.2G and vibration isolation systems maintaining <2.0 mm/s. Our custom nest designs provide 3-point syringe support while precision grippers apply 5-20N controlled force. Validation using high-speed cameras (2000fps) confirms plunger movement ≤0.1mm and silicone layer integrity per USP <1381> requirements.

What methodology ensures 100% needle shield presence and proper placement?

Our multi-camera vision system utilizes 4x 5MP cameras with LED strobe illumination capturing images at 500fps. The system performs 360° inspection detecting: shield presence (99.99% accuracy), proper seating (gap detection ≥0.2mm), and color verification for different needle sizes. Automated rejection occurs within 50ms of detection, with validation data showing Cpk ≥2.0 for shield integrity.

How quickly can format changeover be completed between different syringe sizes (0.5ml to 10ml)?

Our automated changeover system achieves complete transitions in ≤9 minutes using RFID-tagged tooling and recipe management for 150+ syringe configurations. The process includes: nest replacement (3 minutes), handling adjustment (3 minutes), vision recalibration (3 minutes). Validated ±0.2mm repeatability across 400+ change cycles ensures immediate production readiness.

What is the total cost of ownership over 7 years for prefilled syringe blister packaging?

Our TCO analysis shows 42-45% lower costs through: Energy optimization (46% reduction), Maintenance efficiency (38% improvement), Labor savings (55% reduction), and Quality cost avoidance (68% reduction). Annual operating cost is €61,200 with ROI period of 16-18 months based on European energy rates and typical syringe production volumes.

How do you prevent silicone oil contamination and maintain syringe functionality?

We implement non-contact handling using Bernoulli principles and vibration-damped conveying. The system maintains temperature stability (20-25°C) and humidity control (45-55% RH). Validation shows silicone layer uniformity with functionality testing confirming consistent glide force and dose accuracy meeting ISO 11040 requirements.

What level of data integrity supports combination product regulatory requirements?

Our system provides full 21 CFR Part 11 compliance with: Electronic signatures, immutable audit trails, and automated data archiving (10-year retention). The platform monitors >200 parameters with 100% data integrity, supporting combination product submissions per FDA and EMA requirements with complete traceability from raw materials to finished blisters.

How is energy consumption optimized while maintaining precise thermal control?

Our energy management system achieves consumption of ≤0.085 kWh per 100 blisters through: Regenerative drives (recovering 43% energy), IE5 premium motors, and smart thermal control reducing heating energy by 48%. Real-time monitoring shows peak demand of 31.2 kW with ISO 50001 certification validating annual savings of €26,500.

What validation documentation supports biological product submissions?

We provide complete validation packages including: Extractables & Leachables studies, Container Closure Integrity testing, Functionality validation, and Process validation per FDA and EMA guidelines. Documentation includes IQ/OQ/PQ protocols with predefined acceptance criteria and risk assessments per ICH Q9 requirements.

How do you ensure global support for temperature-sensitive biological products?

Our global network maintains ≥99.1% spare parts availability with ≤15-hour emergency delivery. Services include: 24/7 remote monitoring, temperature-controlled logistics, and validation support for cold chain requirements. Customer data shows ≥98.8% equipment uptime with ≤3-hour response time for critical issues affecting product stability, supported by SLA agreements with performance guarantees.

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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Punching frequency:

Boxing capacity: