Preparation Before Starting a Blister Packaging Machine

The preparation before starting a blister packaging machine is a critical step in ensuring production safety, stable operation, and qualified product quality. A standardized preparation process effectively reduces malfunctions, downtime, and material waste. The following is a systematic and detailed pre-start preparation procedure for blister packaging machines, especially suitable for high-demand industries such as pharmaceuticals and food.

Core Objectives

• Safety: Ensure the safety of personnel and equipment.
• Quality: Ensure production conditions meet process requirements and prevent contamination and mix-ups.
• Efficiency: Ensure the equipment is in good condition and the production process runs smoothly.

Standard Start-up Preparation Procedure

Phase One: Production Environment and Personnel Preparation (Approximately 30 minutes before the shift)

1. Environment Check:

• Check if the temperature and humidity of the production area are within the specified range (especially for temperature and humidity-sensitive drugs and food).
• Confirm that the pressure difference and cleanliness of the clean area (if any) meet the requirements.
• Check that the lighting is sufficient and that there are no obstructions to passages and equipment operation.

2. Personnel Preparation:

• Operators wear the prescribed work clothes, hats, and gloves (if required).
• Confirm that personnel are in good mental condition and have received relevant equipment operation and safety training.
• Read the previous shift's "Shift Handover Record" to understand the equipment operating status and pending matters.

3. Document and Tool Preparation:

• Obtain the "Batch Production Instructions" and "Packaging Standard Operating Procedures" for this production task.
• Prepare necessary operating tools (such as Allen wrenches, rags, alcohol, etc.), cleaning tools, and production record forms.

Phase Two: Equipment Status Check and Preparation (Approximately 15-20 minutes before the shift)

1. General Checks (Daily/Every Shift):

• Safety Devices: Check that all safety doors and protective covers are intact and properly closed, and that the emergency stop button is functional.
• Cleanliness: Confirm that the equipment work surface, guide rails, forming station, heat sealing station, hopper, discharge track, and other parts in contact with the product have been cleaned according to the procedure, and that there are no residues or dust from the previous batch. If necessary, wipe with 75% alcohol or the specified disinfectant.
• Lubrication Check: Check the oil level of key lubrication points (such as guide rails, chains, cams) according to the equipment's "Lubrication Check Sheet".
• Air Source and Pressure: Check that the compressed air source is connected and the pressure is stable within the equipment's required range (usually 0.6-0.8 MPa). Power Supply: Check that the main power supply and the control power for each component are properly connected.

2. Functional Inspection:

• Heating System: Turn on the forming heating plate and heat sealing heating plate in advance for preheating to reach and stabilize at the process-specified temperature. Note: Sufficient heating time under no-load conditions is necessary to avoid uneven temperature distribution, which can lead to poor blister formation or insecure sealing.
• Cooling System: Check that the cooling water (circulating water or chilled water) is flowing freely and that the water temperature is normal.
• Vacuum/Forming System: Check that the vacuum pump is operating normally and that the vacuum lines are unobstructed.
• Detection System: Start the visual inspection or missing-part detection system, check that the camera is clean, and that the light source brightness is normal. Functionality can be verified using a test plate or standard sample.

Third Stage: Material Preparation and Loading

1. Material Verification ("Three-Way Verification" Principle):

• According to the production instructions, verify the name, specifications, batch number, and expiration date of the blister base material (PVC/PET film rolls, etc.), cover film (aluminum foil roll), and product (tablets, capsules, etc.) required for this production run.
• Check the appearance of the packaging materials for damage, contamination, or scratches, and ensure that the rolls are flat and wrinkle-free.
• Confirm that the actual product matches the instructions.

2. Material Installation:

• Blister Base Material Installation: Correctly thread the roll onto the unwinding shaft, following the equipment's indicated path through the guide rollers and tension control device, and lead it to below the forming mold. Adjust the tension to an appropriate level.
• Cover Film Installation: Install the aluminum foil roll on the other unwinding shaft, passing it through the preheating roller (if any) and below the heat sealing mold. Pay attention to the correct side (coated side facing the blister base material).
• Product Loading: Pour the product into the cleaned hopper or vibrating screen. For fragile or dusty products, handle gently.

Fourth Stage: Parameter Setting and First Article Confirmation

1. Process Parameter Calling/Setting:

• On the HMI (Human-Machine Interface), call up the preset recipe for this product (including: heating temperatures for each section, heat sealing temperature and pressure, forming depth, step length, cutting position, detection sensitivity, etc.).
• For new products, the parameters must be set and recorded for the first time according to the "Process Specifications".

2. Mold Confirmation:

• Confirm that the installed molding and cutting dies perfectly match the specifications of the product currently being manufactured.
• Manually rotate the machine to check if the mold closes smoothly and without interference.

3. Low-Speed ​​Dry Run and First Article Inspection:

• With no product loaded, jog or run the equipment for several cycles at a low speed (e.g., 10-15% of full speed).
• Check: Is the blister forming uniform and full? Is the aluminum foil running straight? Is the sealing area aligned correctly? Are the waste edges and trimmings being cut and pulled correctly?
• After a successful dry run, begin loading the product and start formal production.
• Produce the first few samples (first 3-5 sheets) and perform key quality checks:

1. Appearance: Blister formation is good, with no perforations or deformation.
2. Sealing: The aluminum foil and blister are tightly bonded, with no wrinkles or leaks.
3. Contents: No missing particles, fragments, or foreign objects; the product is undamaged.
4. Batch Number Printing: Clear, correct, and accurately positioned.
5. Dimensions: Cutting margins meet requirements.

• Only after the first article inspection is successful and recorded can the equipment speed be gradually increased to the normal production speed.

Special Precautions:

• When changing products: A thorough cleanup is required, including equipment cleaning, material removal, and document replacement, and a cleanup record must be filled out to prevent contamination and mix-ups.
• First startup after a long period of downtime: The inspection should be more comprehensive, and it may be necessary to replenish lubrication points and extend the equipment preheating time.
• Safety First: Any preparation and adjustment work must be performed with the equipment completely stopped and the emergency stop button pressed or the power turned off, especially when contacting molds and moving parts.