Tips for Quality Sealed Blister Packs
Pharmaceutical companies worldwide rely on blister packs to ensure the quality and safety of their products, but how do you guarantee that the seal remains intact throughout their shelf life?
Find out tips for creating quality sealed blister packs for your pharmaceutical packaging.
Follow these essential tips to ensure a reliable blister seal that guarantees the safety and stability of your pharmaceutical products:
Match Your Packaging Materials
Material selection will largely be dictated by a combination of cost and the level of barrier protection that is needed to ensure the stability and shelf life of the product. However, the compatibility of base and lidding materials to guarantee seal integrity must be considered. Your material supplier will be able to advise on the optimum combination, but as a general rule of thumb, any lidding foil that’s compatible with PVC won’t be a match with PET. Also, since it isn’t possible to seal directly to PCTFE (Aclar), a speciality coating or PVC layer is needed to ensure a strong bond with the lidding material.
Maximize the Seal Area
According to experts, the ideal distance between each cavity in your packaging design should be at least 5 millimeters. Extend the gap to the outer edge of the card for even more sealing power. Plus, it’s important to seal a larger area before trimming off the excess. This will make sure there are no weak points that could compromise your cargo.
Select Your Seal System Carefully
Your sealing system plays a crucial role in the quality of a seal. Intermittent platen sealing systems may require higher pressure and longer sealing times, resulting in seals at a lower temperature. However, the downside is the air trapped in the blister pockets, which can affect the overall look. On the other hand, rotary sealing systems offer a faster and more efficient solution! They seal at lower pressure and in a shorter time, making them perfect for high-speed production. However, rotary sealing systems need higher seal temperatures and a special knurl design for optimal pocket closure. That’s why they’re commonly used for thermoform packs.
Cold formed foil (CFF) blisters have unique characteristics, such as fragility and larger pocket size, making them better suited for platen sealing.
Optimize Your Sealing Parameters
The key to a successful seal lies in the correct combination of dwell time, pressure, and temperature. Even force distribution across the sealing surface is equally important. Luckily, advancements in technology have given us the tools to conquer these challenges. With thick steel plates that don’t bend, rigid press assembly, and precise geometries, force is evenly distributed for that perfect seal every time. The upper sealing tool is specially designed to activate the adhesive layer in the lidding material, ensuring it is evenly heated for an efficient and reliable seal.
Learn about the thermoforming blister packaging process and how it’s different from cold forming.
Consider Knurl Pattern
The type of knurl pattern used on a sealing tool can affect seal integrity. In the world of packaging, pyramid knurl textures are popular for sealing packs. However, using a flat top knurl can actually improve seal integrity and prevent any ruptures in the layers of materials being sealed. If too much or uneven sealing force is applied, the pyramid knurl can accidentally puncture the lidding foil, compromising the seal. But with a flat top knurl, you can avoid this risk altogether, keeping your packages perfectly sealed and secure. Keep in mind that even the smallest details, like the choice of knurl pattern, can have a significant impact on product quality.
Maintain Sealing Plates
Anodized aluminum plates need regular maintenance to ensure proper sealing performance. Over time, ink build-up on blister packaging machines can distort the knurl pattern and prevent the upper and lower sealing tools from interlocking correctly. This can create weak spots across the seal and even micro-channeling. To prevent any issues and maintain the quality of your packaging, it’s important to strip and re-anodize the aluminum plates periodically. By doing this, you can ensure that your seals are strong, reliable, and visually appealing.
Perform Pack Integrity Testing
Packaging integrity testing is essential for guaranteeing the quality of your packaging. It helps verify the strength of the seal, detect capillaries, and identify any material defects caused during the packaging process. There are several tests available, both destructive and non-destructive, such as blue dye, helium trace gas, force decay, and laser/vision deflection. While the traditional blue dye test is widely used in the pharmaceutical industry due to its low cost and simplicity, it can also be messy and subjective. That’s where camera-based integrity testing comes in! This advanced technology allows packaging operations to increase efficiency while maintaining product quality. By utilizing non-destructive techniques, it saves time, reduces waste, and provides more accurate results.
Consider Post-Production Processes
Ensuring the sterility and safety of these packs is crucial, as they contain lifesaving medical devices. That’s why it’s vital to consider the processes they will face post-production. Manufacturers must take into account every step of the journey, from production to sterilization, to maintain the pack’s integrity.
Key Takeaways
Ascend is your one-stop-shop for all your packaging equipment, including blister packs, bottles, pouches, and medical devices. From the Sepha EZ Blister for low-volume blister packaging to the Sepha VisionScan 3D for rapid leak testing, we have the solutions you need to keep your operation running efficiently. Don’t let your process be a headache. Choose Ascend as your trusted partner for pharmaceutical packaging equipment, tooling, and replacement parts. Contact us today to learn more.
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Ascend Packaging Systems LLC is focused on bottle filling and blister packaging for the pharmaceutical industry. With our mix of self-manufactured and distributed products, we can support our customers with all their packaging equipment needs.
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Ascend Packaging Systems LLC.
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