Automatic Vial Liquid Blister Packing Plastic Injection Cartoning Machine Production Line

Product Description

Product Description

Product Introduction

In the pharmaceutical packaging industry, the integrated production line for tray forming, product loading and cartoning is a full-process automated packaging system that integrates automatic tray forming, product loading, tray insertion, cartoning, coding and rejection. It is specially designed for round bottles and vial products such as vials, ampoules, pre-filled syringes and oral liquids, as well as daily chemical products including facial masks and hand creams.

Through coordinated control via a unified PLC and human-machine interface, the line combines a tray former, tray loader, cartoning machine and supporting units for feeding, labeling, inspection and coding to realize closed-loop production ranging from plastic/paper tray forming and product tray insertion to automatic leaflet folding, carton sealing, batch code printing and defective product rejection, meeting GMP cleanliness and traceability requirements.

Intelligent Blister-to-Cartoning Integrated Line

Technical features

 1. High integration enables full automatic production with unmanned key processes.

2. Unified control and servo system ensure precise operation and stable packaging quality.

3. Widely applicable for medicines, healthcare products, daily chemicals and medical devices.

4. Sanitary dead-angle-free design complies with GMP and supports full traceability.

5. Modular structure allows quick specification change for multi-product production.

6. Compact layout brings high efficiency, lower labor cost and fewer operation errors.

Specification

Automatic Tray Forming, Tray Loading & Cartoning Line
Model Number	PBL250-120CA	PBL350-300	PBL400SZ-400SF	PBL600-120CA	PBL600-500S
Parameters of Blister & Tray Forming Section
Model Number	PBL-250	PBL350	PBL400SZ	PBL600	PBL600
Tray Forming and Blanking Frequency	10-30 times/min, 1-6 blister trays/times	16-30 times/min,  1-6 blister trays/times	16-35 times/min,  1-8 blister trays/times	16-30 times/min,  1-12 blister trays/times	16-30 times/min,  1-12 blister trays/times
Maximum Forming Area	110×260 mm	220×350 mm	220×400 mm	220×600 mm	220×600 mm
Forming and Cutting Stroke Range	30-120mm (Customizable)	50 -220 mm (Customizable)	50 -220 mm (Customizable)	50 -220 mm (Customizable)	50 -220 mm (Customizable)
Blister Specification	(Can be designed according to user requirements)	(Can be designed according to user requirements)	(Can be designed according to user requirements)	(Can be designed according to user requirements)	(Can be designed according to user requirements)
Blister tray material	Non-toxic PVC rigid sheet 0.15-0.35×250mm, spool hole diameter 70-76mm	Non-toxic PVC rigid sheet 0.15-0.5×350mm, spool hole diameter 75mm	Non-toxic PVC rigid sheet 0.15-0.5×400mm, spool hole diameter 75mm	Non-toxic PVC rigid sheet 0.15-0.5×600mm, spool hole diameter 75mm	Non-toxic PVC rigid sheet 0.15-0.5×600mm, spool hole diameter 75mm
Electric Heating Power	PVC preheating plate 2 × 3 KW	PVC preheating plate 2 × 3 KW	PVC preheating plate 2 × 4.5 KW	PVC preheating plate 2 × 4.5 KW	PVC preheating plate 2 × 4.5 KW
Cooling methods for blister molds	13°-15° tap water or circulating water 60 L/h	13°-15° tap water or circulating water 60 L/h	13°-15° tap water or circulating water 60 L/h	13°-15° tap water or circulating water 60 L/h	13°-15° tap water or circulating water 60 L/h
Main Motor Power	2.2KW	2.2KW	2.2KW	2.2KW	2.2KW
Parameters of Cartoning Machine Section
Model Number	ZHJ-120CA	ZHJ-300	ZHJ-400SF	ZHJ-120CA	ZHJ-500S
Carton Specification	(65-180)×(45-80)×(15-65)mm	(75-210)X(33-85)X(16-65)mm	(75-210)×(33-85)×(15-75)mm	(100-300)×(45-210)×(15-65)mm	(75-210)×(33-85)×(15-75)mm
Carton Weight	300-350g/m2	300-350g/m2	300-450g/m2	300-450g/m2	300-450g/m2
Leaflet Specification	(100-260)×(100-190)mm	(100-260)X(100-190)mm	(60-200)×(90-300)mm	(100-260)×(100-190)mm	(60-200)×(90-300)mm
Leaflet weight	65-75 g/m² (Offset printing paper)	65-75 g/m² (Offset printing paper)	65-75 g/m² (Offset printing paper)	65-75 g/m² (Offset printing paper)	65-75 g/m² (Offset printing paper)
Cartoning speed	50-60 boxes/min	200 boxes/min	200-350 boxes/min	50-60 boxes/min	400 boxes/min
Power Supply	380V 50Hz	380V 50Hz	380V 50Hz	380V 50Hz	380V 50Hz
Main Motor Power	1.5KW	2.2KW	3.7KW	1.5KW	3.7KW
Production line overall specifications
Overall Equipment Dimensions	7130×2570×1717mm	10780×2600×1900mm	13000×2600×2000mm	9545×2150×1750mm	13400×2600×2000mm
Total Machine Weight	2600 kg	9000 kg	11000 kg	3500 kg	12000 kg
Total Machine Power	15KW	22KW	35KW	18KW	38KW
Maximum Total Air Consumption	480L/ min	480L/ min	500L/ min	580L/ min	500L/ min
Total Air Supply Pressure	0.6-0.8Mpa	0.6-0.8Mpa	0.6-0.8Mpa	0.6-0.8Mpa	0.6-0.8Mpa
The machine parameters mentioned above are for reference only. The specific parameters are designed based on the customer's samples.

Machine structure detail images

Blister Tray Molding Structure

 The blister forming process forms a complete closed loop consisting of material feeding, preheating, forming, inspection, cooling and traction conveying. The material support rod holds and conveys the PVC packaging film, which is pulled forward at a constant speed by the traction mechanism. The PVC sheet is first evenly preheated and softened by the preheating plate, and then enters the forming station to be formed into standard blister trays under the action of compressed air. The formed blister trays undergo online quality inspection via the forming inspection device and are cooled and shaped simultaneously. Finally, the rear roller traction mechanism continuously pulls and conveys qualified blister trays smoothly to the next process, realizing continuous and stable automatic forming operation.
 

Automatic Material Arranging & Feeding Mechanism

The microwave vibratory feeder arranges and conveys bottles including ampoules, vials and oral liquid bottles at a constant speed, and pushes the materials stably to the special positioning tray to complete sorting and posture calibration before loading. Then the Yamaha 4-axis robot grabs, transfers and places the materials accurately into the corresponding cavities of the PVC blister tray in order as per the production rhythm. After tray insertion, the rear pressing mechanism compacts and fixes the materials synchronously to prevent displacement, shaking and falling off, ensuring stable posture and accurate positioning of materials during conveying, and completes the full-automatic loading process completely.

Visual Inspection and Film Sealing Device

After loading, the material-loaded blister trays are conveyed by the traction mechanism to the visual inspection station. The vision system conducts online inspection for defects such as broken bottles, missing filling, liquid leakage and misalignment. Unqualified products are automatically marked and rejected, while qualified ones proceed to the next process.
Qualified blister trays are then sealed by the film sealing unit to ensure tight, reliable sealing without gaps or wrinkles, guaranteeing cleanliness and safety of the products.
The sealed sheets are accurately punched into individual, neatly trimmed blister trays according to preset specifications. The finished trays are smoothly transferred to the next transfer station, completing the whole station process.

Blister Tray Transfer and Conveying Mechanism

This integrated line adopts an automatic transfer mechanism to realize the posture conversion and process connection of blister trays. A Yamaha four-axis robot is installed at the discharge end of the blister packaging machine to flip horizontal blister trays to vertical and transfer them to the transition conveyor.

A Delta spider robot then grips the vertical blister trays and places them accurately at the feeding position of the cartoning machine, completing automatic transfer and loading to ensure efficient and stable operation of the entire line.
 

Automated Cartoning Process

After loading, the materials are conveyed to the cartoning machine conveyor belt and then enter the automatic cartoning process. First, the materials are accurately placed at the feeding station for preliminary inspection to ensure there is no damage or abnormalities before starting the automatic cartoning process. The equipment automatically folds the instruction manual, and the automatic box-opening mechanism picks up and opens the box. Then, the pusher device accurately feeds the materials and instruction manual into the formed carton, completing the initial cartoning.

Company Profile

50000m² PROPRIETARY FACTORY

Founded in 2019, Haichen Machinery is a high-tech enterprise integrating R&D, manufacturing and service, specializing in pharmaceutical, packaging and food machinery. The company boasts a 50,000-square-meter production base and has passed ISO9001 quality management system certification. All its production equipment has obtained CE certification. We primarily design and manufacture fully automatic blister packaging machines, cartoning machines, case packing machines, film strapping machines, labeling machines, and complete packaging production lines. The company's annual output is 500 sets of equipment, with an annual turnover of 80 million RMB.
The company owns multiple patents and a professional R&D team. Its products serve pharmaceutical, food, cosmetic and chemical industries, selling to over 30 provinces in China and more than 100 countries worldwide. Adhering to quality and innovation, it offers customized turnkey solutions for global customers.

Certifications

FAQ

Q1: Where is your factory located? How can I visit?

A1: Our factory is located in Ruian City. If you have plans to visit, we warmly welcome you. We can arrange pick-up from Wenzhou Longwan Airport (Airport code: IATA code: WNZ; ICAO code: ZSWZ) or Ruian Railway Station.

Q2: What about after-sales service and warranty period?,

A2: We provide a 1-year warranty from the date of machine delivery. We have a professional team and experienced technicians who can provide overseas service and offer the best after-sales service to ensure the machine's lifetime use.

Q3: How can I determine if your machine is suitable for my product?

A3: If you don't mind, you can send us material samples, and we will test them on the machine. Before machine production, we will draw up design drawings and send them to you, or we can demonstrate them online via video chat. We will only begin assembling the machine after confirmation.

Q4: Do you provide overseas after-sales service?

A4: We will provide an English operation manual for each machine and offer online operation training. If you require us to train your workers at your factory, the cost will be borne by the customer.

Q5: What about the delivery time?

A5: Delivery time varies depending on the machine's technical complexity and degree of customization.