Define the barrier
State moisture, oxygen, light, microbial and tamper-evidence requirements without assuming one material solves every risk.
DPP-260/360K project platform
Syringe Blister Packing Machine
Configure a flat-plate blister line around the actual syringe, blister drawing, forming depth, loading method and lidding material. HIJ starts from the documented DPP-260/360K platform and freezes syringe-specific tooling through sample trials.
245 × 112 mm forming area
12 mm standard depth
25 mm special-machine depth
Mechanical or servo traction
40–120 mmPublished adjustable feed-stroke range.
40 cycles/minMaximum Alu/PVC blanking reference for the documented 57 × 80 mm × 4 layout.
11 kWPublished total-power reference for the documented platform.
3000 kgPublished reference machine weight.
Quick answer
What is a syringe blister packing machine?
It is a blister forming, loading, sealing, coding and cutting system configured to protect a syringe in a dimensioned cavity. The syringe is not a free-flowing tablet: its barrel, plunger, flange, tip cap and needle shield make cavity depth, orientation and gentle loading central to the project.
Documented DPP-260/360K platform scope
- PVC/PVDC/PE and Alu/PVC or Alu/Alu blister processing
- Contact heating and positive-pressure forming
- Flat-plate heat sealing with air-cushion lift at stop
- Mechanical or servo web traction
- Missing-product detection and reject capability
- Batch marking, indentation and final punching
Syringe-specific scope to freeze in the URS
- Syringe drawing, orientation and acceptable contact points
- Manual, fixture-assisted or automatic loading method
- Cavity depth and flange/plunger clearance
- Forming and lidding material compatibility
- Sterilization path and package-integrity test method
- Vision inspection, rejection and downstream transfer
Important: the standard DPP platform uses a product feeder intended for tablets or capsules. A syringe project requires a separate loading concept; automatic syringe placement must not be assumed until HIJ approves samples, tooling and the handling design.
Package architecture
Select forming and lidding materials from the protection requirement
The machine cannot define the package alone. The barrier target, syringe condition, sterilization route, opening method and shelf-life study determine the forming web, lidding and seal-validation work.
| Material path | Verified platform position | Project decision |
|---|---|---|
| PVC / PVC-PVDC / PE forming web | Listed in the DPP-260/360K material specification; positive-pressure forming is documented. | Confirm thickness, roll geometry, cavity depth, syringe retention and the selected lidding seal window. |
| Alu/PVC with aluminum lidding | Documented flat-plate Alu/PVC packaging configuration with coated PTP aluminum foil. | Confirm peel or push-through opening behaviour, printing and seal-integrity protocol. |
| Cold-form Alu/Alu | Alu/Alu function is documented. Standard forming depth is 12 mm; the source lists 25 mm for a special machine. | Compare the complete syringe envelope with the special tooling limit before quotation. |
| PET-G or Tyvek combinations | Not proven as standard materials in the current DPP-260/360K file. | Require film supplier data, forming/sealing trials and written confirmation of station changes before purchase. |
Define sterilization timing
Clarify whether the syringe arrives sterile, the package is sterilized after sealing, or the blister is only secondary protection.
Validate the final pack
Set seal strength, leak or integrity testing, opening behaviour and stability evidence in the customer quality plan.
Station-by-station
How the syringe blister packaging process is configured
The documented machine sequence covers web handling through punching. Syringe loading is inserted as a project-specific station between forming and inspection.
Unwind
Motor-assisted roll unwinding reduces traction resistance and monitors the end of the forming web.
Heat and form
Contact heating softens the web before positive compressed-air forming creates the specified cavity.
Load the syringe
Use the approved manual, fixture-assisted or custom manipulator method without disturbing the plunger, cap or shield.
Inspect
Confirm presence and position before sealing. Camera detection and reject logic must match the approved inspection scope.
Seal
Flat-plate heat sealing joins the lidding to the formed web; pressure, temperature and dwell belong in the recipe and OQ.
Mark and pull
Batch information is impressed and mechanical or servo traction advances the web at the selected stroke.
Punch and transfer
The punch cuts the agreed blister layout; an optional plate-suction device can support downstream conveyor transfer.
Published platform data
DPP-260/360K specifications relevant to a syringe project
These values come from the formal DPP-260/360K file. They describe the blister platform, not a guaranteed syringe output. HIJ must calculate the finished result from the syringe and blister layout.
| Parameter | Published reference | Syringe-project note |
|---|---|---|
| Platform | DPP-260/360K flat-plate medium-speed Alu/PVC and Alu/Alu blister machine | Medical-device and ampoule applications are included in the documented scope. |
| Maximum forming area | 245 × 112 mm | Fit the full blister layout, flange clearance and cutting margin inside this envelope. |
| Maximum forming depth | 12 mm standard; 25 mm special machine | Compare against the largest syringe diameter, cap or shield and retention geometry. |
| Feed stroke | 40–120 mm adjustable | The selected blister pitch must remain within the usable stroke. |
| Maximum blanking reference | 40 cycles/min for standard 57 × 80 mm × 4 Alu/PVC layout | This is a cycle reference, not a guaranteed syringe blister output. |
| Forming web | Pharmaceutical PVC, typically 0.25–0.30 mm; published range 0.15–0.50 mm | Final material and thickness require forming trials. |
| Lidding | Single-side coated PTP aluminum foil, 0.02–0.025 mm | Other lidding such as Tyvek requires separate written technical confirmation. |
| Total power | 11 kW, three-phase 380 V 50 Hz; 220 V 60 Hz listed | Confirm site electrical standard and the load of project options. |
| Compressed-air flow | 0.25 m³/min reference | Confirm clean, dry air pressure and quality in the utility schedule. |
| Machine dimensions | 4470 × 1100 × 1740 mm | Allow clearance for rolls, tooling, loading and maintenance. |
| Machine weight | 3000 kg | Reference machine weight for floor-loading and handling review. |
| Traction | Mechanical or servo traction | Servo traction supports accurate, adjustable web advance when specified. |
| Controls reference | Siemens HMI/PLC/servo/inverter; Omron detection components | The formal list states that final configuration is subject to the contract. |
Handling architecture
Choose the loading method before quoting automatic output
Loading usually becomes the limiting station because the syringe must arrive in the correct orientation without moving the plunger or damaging the cap, shield, flange or printed barrel.
Manual loading
- Useful for validation, pilot batches and low output
- Lowest feeding complexity
- Requires ergonomic reach and operator-rate study
- Must include presence checks before sealing
Fixture or tray-assisted loading
- Maintains orientation outside the blister machine
- Reduces direct handling of individual syringes
- Needs defined tray pitch and transfer interface
- Useful bridge between manual and full automation
Custom automatic loading
- Manipulator or project-specific pick-and-place concept
- Requires representative syringes and rate trials
- Needs no-damage and orientation acceptance rules
- Final design and output belong in the contract
Inspection scope
Inspect what can make the finished pack unacceptable
The base source includes missing-product detection and reject capability. Syringe-specific camera checks should be selected from the actual defect list, not added as a generic “vision system”.
- Syringe present in every cavity
- Correct orientation and seating
- Plunger, cap and shield position
- Seal-area contamination or trapped parts
- Printed code and artwork position
- Reject confirmation and batch counter
Changeover rule: quote changeover from the real list of changed parts—forming tool, loading fixture, seal tool, code, punch and inspection recipe. No fixed changeover time is published without a witnessed format-change test.
Quote and acceptance scope
Six inputs HIJ needs before configuring a syringe blister line
These inputs control the machine format, loading method, material trials, inspection, documentation and project price.
Syringe set
Dimensioned drawings, samples, barrel material, flange, plunger, tip cap, needle shield and acceptable contact points.
Blister layout
Units per pack, orientation, cavity depth, opening method, retention requirement and cutting outline.
Material system
Forming web, lidding, thickness, roll dimensions, artwork, sealing window and supplier samples.
Good output
Sustained accepted packs per minute, batch size, shifts, loading availability and changeover frequency.
Quality plan
Inspection defects, integrity tests, sterilization route, traceability, qualification documents and release criteria.
Line interfaces
Upstream handling, downstream cartoning, coding, rejection, utilities, room layout and data requirements.
FAT evidence
Test the nominated syringe, material and production tooling
Agree the sample quantity, run duration, acceptance rate, reject definition and open-item process before FAT. Documentation such as DQ/IQ/OQ protocols is supplied only when included in the approved contract scope.
- Cavity dimensions and syringe retention
- Loading rate and no-damage evidence
- Presence, position and reject challenges
- Seal parameters and integrity samples
- Coding, web registration and punching
- Alarms, recipes, counters and changeover
- Utilities and downstream handshakes
- Signed results, videos and open items
Frequently asked questions
Syringe blister packing machine FAQ
The approved URS, tooling drawing, samples and FAT results own the final machine configuration.
Which HIJ platform is used for a syringe blister project?
HIJ can evaluate the documented DPP-260/360K flat-plate blister platform for medical-device and ampoule applications. The syringe-specific cavity, loading, inspection, sealing and cutting design is engineered from the customer's samples and URS rather than assumed from a catalog model name.
What production output should a buyer use for planning?
The formal platform source gives a maximum reference of 40 blanking cycles per minute for a standard 57 × 80 mm × 4 Alu/PVC layout. This is not a guaranteed syringe output. Finished packs per minute depend on blister layout, loading method, material, inspection and acceptance criteria.
Which syringe sizes can the machine handle?
There is no verified universal syringe-volume range in the current source. Suitability is determined from the complete syringe envelope, especially barrel diameter, flange, plunger, tip cap or needle shield, and the documented 12 mm standard or 25 mm special-machine forming-depth limit.
How are syringes loaded into the blister cavities?
Projects may use manual loading, fixture or tray-assisted loading, or a custom manipulator. Automatic loading is not a standard assumption; HIJ must prove orientation, no-damage handling, rate and recovery using representative syringes.
Which forming and lidding materials are supported?
The DPP-260/360K file documents PVC/PVDC/PE forming materials, Alu/PVC and Alu/Alu configurations, and coated PTP aluminum lidding. PET-G or Tyvek combinations require material data, trials and written confirmation of the forming or sealing configuration.
Does the blister machine make the syringe package sterile?
No. The packaging machine forms and seals the pack; sterility depends on the product state, cleanroom and handling controls, sterilization route, material system and validated process defined by the customer. These responsibilities must be separated in the URS.
What should be tested during FAT?
Test cavity dimensions, syringe retention, loading without damage, presence and position challenges, sealing, coding, punching, rejection, alarms, counters and changeover. Use the nominated syringe, forming web, lidding and production tooling with agreed sample quantity and acceptance rules.
How much does a syringe blister packing machine cost?
Price depends on the forming and sealing platform, cavity tooling, loading automation, inspection, coding, auxiliaries, documentation and line integration. Send the syringe drawing, blister layout, materials and required good output so HIJ can issue an itemized project quotation instead of an unreliable headline price.
Project inquiry
Configure the line around your real syringe and blister
Send the six inputs below. HIJ can return the platform, tooling, loading, inspection, documentation and FAT scope as separate quotation items.
1. Syringe drawings and samples
2. Blister layout and cavity depth
3. Forming and lidding materials
4. Required sustained good output
5. Inspection and quality scope
6. Utilities and line interfaces