A fully integrated blister cartoning machine that forms PVC/ALU trays, robot-loads glass pre-filled syringes and ampoules, heat-seals, punches and cartons them on one line — driven by a Siemens CPU1516T, Yamaha 4-axis robots and a German GUK leaflet folder. cGMP-ready and CE-marked.
A blister cartoning machine (blister cartoner) loads filled pharmaceutical blisters and a folded leaflet into a carton, then closes, seals and codes it automatically. The HIJ PBL-400S-400SF goes further — it forms the PVC/ALU blister, robot-loads pre-filled syringes or ampoules, heat-seals and punches the tray, then cartons it, all on one integrated line at 6,000–10,000 pieces per hour.
The cartoning section alone can run up to 300 cartons/min, with a product-first interlock: no product means no leaflet pick, no carton suction and no push, so only complete, batch-coded cartons leave the line. Forming, robotic loading, sealing, punching, leaflet folding and cartoning are synchronised by Siemens servo motion control.
For lower-volume or mixed pharmaceutical lines that don't need integrated forming and robotic loading, the same secondary-packaging job is handled by our WZTS-130 automatic cartoning machine at 30–80 cartons/min.
Key Takeaways — At a Glance
The PBL-400S-400SF is an integrated blister cartoning line: it forms, robot-loads, seals, punches and cartons on one frame — no separate blister machine and cartoner to synchronise.
Output is 6,000–10,000 syringes or ampoules per hour; the cartoning section is mechanically rated up to 300 cartons/min.
Loading uses Yamaha 4-axis robots with vacuum grippers and 3 Siemens tracking servos — built for fragile glass pre-filled syringes.
A product-first interlock rejects 100% of missing-syringe and empty-carton events, so only complete, batch-coded cartons leave the line.
Control is a Siemens CPU1516T motion PLC with SINAMICS S210 servos and a touchscreen with electronic signature and audit trail to support your 21 CFR Part 11 program.
The 14-metre line runs with only 1–2 operators; delivery ~120 days after deposit and approved drawings, with a 12-month warranty.
Technical Data
PBL-400S-400SF Specifications
Line & General
Model
PBL-400S-400SF Integrated Blister Cartoning Line
Output (syringes / ampoules)
6,000–10,000 pcs/h
Cartoning capacity (max.)
up to 300 cartons/min
Power supply
380 V, 50 Hz
Total machine power
35 kW
Air consumption (max.)
500 L/min
Air supply pressure
0.6–0.8 MPa
Overall dimensions (L×W×H)
14000 × 2500 × 2000 mm
Weight
~10,000 kg
Operators required
1–2 for the whole line
Blister Forming Section
Punching frequency
10–30 times/min
Max. forming area
220 × 400 mm
Forming stroke (servo)
50–220 mm
Blister film
Rigid PVC / PVDC / Alu-Alu, 0.15–0.5 mm × 400 mm (Ø up to 450)
From PVC unwinding to vision-checked discharge — the real subsystems of the PBL-400S-400SF, with Siemens motion control, Yamaha robotics and a German GUK leaflet folder.
Blister Forming
PVC film unwinding & guide rollers
Film unwinding & tension guide (PVC up to Ø450 mm, change without stopping)
PVC/ALU forming mold station (max forming area 220×400 mm)
PVC/ALU film is preheated and positive-pressure formed into trays; empty-blister detection rejects defects.
2
Robot-Load
Syringes/ampoules are sorted by star-wheel; a Yamaha 4-axis robot loads them into the trays.
3
Seal & Cut
Rotary heat-sealing laminates the foil; the eccentric punch cuts cards burr-free; scrap is recovered.
4
Track & Transfer
A Yamaha tracking manipulator (3× Siemens servos) places blisters into the cartoner compartments.
5
Fold Leaflet
The GUK C91 folder folds the leaflet 1–4 times, synchronized to the cartoning chain.
6
Open & Load
A 4-head gear opens 4 cartons per rotation; double pushers insert leaflet then blister.
7
Code & Seal
Steel-embossed 3–4 line batch coding, then tongue-tuck sealing.
8
Inspect & Discharge
Empty-carton/metal detection rejects incompletes; good cartons are discharged.
Applications
Built for Sensitive Pharma Products
Pre-Filled Syringes
Glass syringes robot-loaded into PVC/ALU trays with missing-syringe rejection.
Glass Ampoules
Gentle handling and forced detection for fragile glass ampoules.
Alu-Alu Blisters
Moisture-sensitive drugs in cold-form aluminium-plastic blisters.
Tablets & Capsules
PVC/PVDC blister formats with leaflet, configurable feeders.
Line Configuration
Integrated Blister Cartoning Line vs Standalone Machines
Buyers usually choose between one integrated blister cartoning line like the PBL-400S-400SF, or a standalone syringe blister packing machine connected to a separate cartoner. Here is how the two configurations compare in practice.
Factor
Integrated Line (PBL-400S-400SF)
Standalone Blister Machine + Separate Cartoner
Synchronisation
One Siemens CPU1516T controls forming, robots, folder and cartoner — factory-synchronised, no interface engineering
Two PLCs, two HMIs; conveyor handshake and rejection logic must be engineered and validated on site
Laser-coded, numbered parts; Siemens touchscreen with electronic signature and audit-trail to support 21 CFR Part 11 requirements.
cGMP-Ready Documentation
Supports your own DQ/IQ/OQ/PQ validation; CE-marked, ISO 9001 build, 100% missing-product rejection.
"Cartoning glass pre-filled syringes is unforgiving — a fragile product, a leaflet and a carton all have to meet at speed without a single broken barrel. That's why this line uses a Yamaha 4-axis robot for loading, three Siemens tracking servos for transfer, and forced photoelectric-plus-mechanical detection that rejects 100% of missing syringes. Nothing leaves without a product, a leaflet and a code.— Forester Xiang, Founder & Chief Engineer, HIJ Machinery
Blister Cartoning Machine FAQ
What is a blister cartoning machine?
A blister cartoning machine loads filled pharmaceutical blisters and a folded leaflet into a carton, then closes, seals and codes it automatically. HIJ's PBL-400S-400SF integrates PVC/ALU forming, robotic loading and cartoning on one line, running 6,000–10,000 pieces per hour.
What is the output of the PBL-400S-400SF?
The line outputs 6,000–10,000 syringes or ampoules per hour. The cartoning section itself has a mechanical capacity of up to 300 cartons per minute; actual throughput is paced to the product and carton format.
Which products and blister materials does it handle?
It is configured for glass pre-filled syringes and ampoules, and also runs tablets and capsules. Blister film is rigid PVC, PVDC or Alu-Alu (0.15–0.5 mm). Carton size ranges from 65×33×15 mm to 180×85×75 mm.
What robotics and control system does it use?
A Siemens CPU1516T motion PLC with SINAMICS S210 servos, Yamaha 4-axis robots for loading and transfer, three Siemens tracking servos, a German GUK C91 leaflet folder, and SICK, Festo, OMRON and Pepperl+Fuchs sensing — over 90% imported components.
Is it suitable for pharmaceutical cGMP production?
Yes. The line is cGMP-ready and CE-marked, built to ISO 9001 manufacturing standards with 100% missing-syringe and empty-carton rejection, laser-coded traceable parts, and a touchscreen with electronic signature and audit trail. HIJ supplies documentation that supports your own internal validation and regulatory submissions; your facility performs the validation.
How much does the PBL-400S-400SF cost?
This is a bespoke integrated line; price depends on feeders, product, validation and destination. It is quoted per configuration — typically a strong saving versus comparable European syringe-cartoning lines. Request a custom quote.
What are the delivery, payment and warranty terms?
Delivery is about 120 calendar days after the deposit and approved drawings. Payment is T/T, 40% advance and 60% after FAT before delivery, FOB/CIF China in seaworthy wooden cases. Warranty is 12 months from arrival, with free quality spare parts and whole-life maintenance.
Send us your product (syringe / ampoule / tablet), blister format and output target — Forester's team will configure the line and quote a complete, validated solution.
HIJ Machinery is a pharmaceutical packaging machinery manufacturer based in Rui'an, Wenzhou, China, founded in 2004. It builds cartoning and blister machines — including the PBL-400S-400SF blister cartoning machine for pre-filled syringes and ampoules, with Siemens CPU1516T control, Yamaha 4-axis robots and a German GUK leaflet folder — to a cGMP-ready, CE-marked, ISO 9001 manufacturing standard. Founder Forester Xiang has 20+ years of experience and has audited 100+ pharmaceutical facilities across 30+ countries.
