Flexibility in packaging
This compact blister packaging line is ideal for small runs

Compact and well-thought-out, the Blister Express Center from Uhlmann Pac-Systeme is a good choice for
packaging runs of up to 15,000
blisters, which account for most pharmaceutical production.

With the launch of its Blister Express Center (BEC), Uhlmann Pac-Systeme has created a new era in pharmaceutical packaging. The BEC is a networked system comprising a thermoformer, a cartoner and a stretchbander, plus all the equipment and software needed to integrate production planning and material supplies. It is designed to meet GMP standards and to ensure consistent high quality and safety. With its ability to work unattended operation and with a changeover time of 15 minutes, the BEC is the perfect solution for the economical and flexible packaging of small and medium-sized batches of 500–15,000 blisters. On average, large packaging runs now account for only 15–30% of total production, and medium-sized runs for another 25%. That
leaves around half of all production needing to be packed in small batches, which are completely uneconomic for high-
speed packaging lines. The availability of the BEC means that high-speed machines can now be reserved for the job they do best.
Uhlmann’s BEC is a single-lane machine that squeezes thermoforming, cartoning and stretchbanding modules into a length of 8 m, making it 50% shorter than conventional lines. But small does not
mean basic: the BEC has a large number of innovative features.
A total of 26 synchronized servo drives automatically control all drive functions and position the blisters, cartons and leaflets with pinpoint accuracy. The use of servo technology throughout also makes changeovers much easier. With pre-programmed settings, small lightweight tools and only 22 format parts, a team of trained operators can carry out a size change in just 15 minutes.
All three modules are controlled by a central operating and visualization system with a touch screen. This stores and manages format-specific and order-specific data for the complete line, reducing manual format adjustments to a minimum.
Direct transfer from one unit to the next increases process safety, while the uniform design of the three modules reduces the spare parts inventory and simplifies maintenance.
All the foils, product, cartons and leaflets needed for the run can be loaded in advance, for true unattended operation. With two BECs running in parallel, on-stream time can reach 80–90%, an exceptional figure for the pharmaceutical industry.

Integration and
programmability
Servo technology is at the core of the BEC. In the first step, the forming material is unwound, heated and formed
into blisters. As well as PVC, the
system can handle PP, PVDC, Aclar and aluminum flawlessly and with minimum initial wastage. The thermoforming module has a capacity of 100 blisters per minute.
The formed web is then filled with product and the blister position is checked by a laser control system. After the blisters have been code-embossed and perforated, they are punched out and placed directly into the product transport system of the cartoner. This allows product stacks to be formed with heights of up to 85 mm. Partially filled blisters are rejected and collected separately.
The cartoner transports only complete blister stacks, runs with no need for manual adjustments to the carton feeder, and can be loaded with up to 5,000 cartons and leaflets. For larger batches, an optional
loading system called the PacLoader adds capacity for another 10,000 cartons.
Setting the carton width, leaflet feeding and product loading are all servo-controlled using the batch-
specific data stored in the process computer.
Using servo drives to stretch and seal the polyethylene film, the stretchbanding module can handle even the smallest
batches. It wraps up to 25 bundles per minute, each consisting of up to 80 small or up to 40 large cartons. The numbers of layers and rows can be programmed freely, and cartons can be stacked either flat or standing on edge. Uhlmann also works with customers to adapt the system to their specific requirements.
Logistics and
documentation
Even the perfect machine does not guarantee 100% productivity, because so much depends on the availability of materials and parts. Accordingly, the BEC was designed with its own logistics system. All the necessary packaging materials, tools and format parts are held in the Uhlmann Shuttle, a miniature high-shelf storage system, and the system includes trolleys for transporting foils, products and format parts. As a result, both operations scheduling and material supplies can run like clockwork.
Practical software
tools
Practical software tools complement the BEC. One program looks after production planning for every batch over a given period of time. It recommends on which line, on which day, and at what time each job should run, and manages tools and format parts.
Another application handles data acquisition, allowing data on contracts and machines to be collected, visualized, controlled and evaluated. Efficiency and utilization factors are always to hand, while prompt analyses enable equally prompt reactions and so best use of the machine’s potential.
With its flexibility, power and ability to handle small batches economically, the Blister Express Center perfectly meets the challenges of modern pharmaceutical packaging.