Routine maintenance of blister packaging machines is the core of preventive maintenance and is crucial for ensuring long-term stable operation, reducing unexpected failures, extending service life, and guaranteeing packaging quality (especially the airtightness of pharmaceuticals). Standardized routine maintenance can significantly reduce repair costs and production losses.
The following is a systematic routine maintenance procedure for blister packaging machines, divided by maintenance cycle and key components.
Core Maintenance Principles
- Safety First: All maintenance must be performed with the power and air supply disconnected and the equipment completely stopped, and warning signs must be posted.
- Prevention is Key: Conduct regular inspections to address minor problems before they escalate.
- Cleanliness is Fundamental: Maintaining the cleanliness of the equipment, especially the product contact areas, is the basis for preventing contamination and malfunctions.
- Record Keeping: All maintenance work must be recorded for traceability and analysis.
I. Per Shift/Daily Maintenance (Operator Responsibility)
This is the most basic maintenance, performed before and after production and during shift changes.
1. Cleaning
- Product Contact Areas: Use a lint-free soft cloth and approved cleaning agents (such as 75% ethanol) to thoroughly clean all parts that come into direct contact with the product, such as the hopper, vibrating plate/guide rails, discharge chute, and filling station, to prevent cross-contamination and material buildup.
- Forming and Heat Sealing Areas: Clean any residual plastic debris, aluminum foil particles, or burnt material from the surface of the forming and heat sealing molds. Note: The molds are hot; wait until they have completely cooled before cleaning to prevent burns and deformation.
- External Machine Body: Wipe the equipment casing, control panel, and display screen to keep them clean.
- Waste Area: Clean the waste (edge material, waste blisters) collection bin to ensure smooth waste discharge.
2. Inspection and Check
- Safety Check: Confirm that the emergency stop button, safety door locks, and protective covers are intact and functional.
- Pneumatic System Check: Drain accumulated water from the three-unit combination (filter, pressure regulator, lubricator), check the oil level in the lubricator and replenish with dedicated lubricating oil as needed. Confirm stable air pressure.
- Lubrication Check: Visually inspect the surfaces of the guide rails, sliders, and cams for an oil film, and add a small amount of lubricating oil as needed.
- Key Components Listening/Observation: Listen for any abnormal noises during operation (such as impact or friction sounds), and observe for any abnormal vibrations.
II. Weekly Maintenance (Operator/Maintenance Technician jointly responsible)
Perform more in-depth cleaning and inspection.
1. Deep Cleaning
- Disassemble easily removable parts (such as some guide rail covers, small guide wheels) for cleaning.
- Clean the lenses of photoelectric sensors and vision inspection cameras to ensure that dust and oil stains do not affect detection accuracy.
- Clean dust from cooling fans and vents to prevent equipment overheating.
2. Key Part Inspection and Lubrication
- Transmission System: Check the tension of chains and timing belts, and adjust if necessary. Apply lubricant to specified parts according to the equipment manual.
- Vacuum System: Check the vacuum pump oil level (if applicable), clean or replace the vacuum filter element.
- Heating System: Check if the wiring of the heating plate (rod) is loose, and if the thermocouple is securely installed.
III. Monthly/Regular Maintenance (Maintenance Technician/Engineer responsible)
Systematic inspection, adjustment, and component replacement are required.
1. Mechanical System
- Comprehensive Lubrication: Apply the specified grade of grease or lubricating oil to all lubrication points (ball screws, bearings, gears, etc.) according to the lubrication chart.
- Tightening Check: Use a torque wrench to check and tighten bolts in critical areas (such as mold mounting bolts, frame connection bolts) to prevent loosening due to vibration.
- Wear Inspection: Check if the sealing strips (heat-sealing silicone plates) are damaged, aged, or indented, and replace them promptly. Check the wear of each guide bearing and slider.
2. Electrical and Control System
- Check the operating status and heat dissipation of each motor and servo drive.
- Clean dust from the electrical control cabinet (use a vacuum cleaner; strictly prohibit using an air gun to blow directly, as this may blow dust into deeper areas).
3. Pneumatic System
- Thoroughly check air pipe joints for leaks.
- Clean or replace the filter element of the pneumatic three-unit assembly.
- Check if each cylinder is operating smoothly and without crawling.
4. Mold Maintenance (Very Important)
- Remove the forming lower mold and cutting lower mold, soak them in a special cleaning agent, and thoroughly remove residual plastic and dirt.
- Check if the mold's vent holes are blocked and clear them with a fine needle.
- Check if the mold edges are sharp and free of nicks; perform professional sharpening if necessary.
Special Precautions:
- Lubricant Selection: Only use lubricants/greases of the type recommended by the equipment manufacturer, especially in areas near product contact. Food-grade or pharmaceutical-grade lubricants must be used to prevent contamination.
- Mold Maintenance: The mold is a critical and expensive component. Use specialized tools for handling and cleaning, and handle with care to prevent damage.
- Recording and Analysis: Record in detail the maintenance performed, problems found, and corrective actions taken. Conduct root cause analysis for frequently occurring failures of the same type and improve the maintenance plan.
- Personnel Training: Ensure that operators and maintenance personnel fully understand the equipment structure, maintenance points, and safety procedures.
Summary: Daily maintenance of a blister packaging machine is not simply "wiping down the machine," but a systematic preventive engineering process. Systematizing, documenting, and assigning responsibility for maintenance work is the foundation for ensuring the equipment remains in optimal condition and achieving high-efficiency, high-quality, and low-cost production. Strict daily maintenance is the most economical form of repair.