Blister and Strip Packaging Systems – Formatting Kits & Mold Solutions
Blister and strip packaging machines are one of the most sensitive production areas in the pharmaceutical industry. One of the most critical components of these machines is... format teams, It must be specifically designed according to the product shape, packaging material, and dosage form. Although we are not the manufacturer of these machines, we offer high-precision solutions. format molds, upper and lower printing plate sets, cutting units and embossing tools We specialize in its production.
🔩 Our Format Team Production Services
In full compliance with GMP standards in the pharmaceutical industry, we provide the following solutions tailored to different blister structures and machine brands:
- Blister Format Sets (Alu-Alu, Alu-PVC, Alu-PVDC, OPA-Alu)
- Strip Packaging Format Sets
- Custom mold design for product forms such as tablets, capsules, and softgels.
- Cutting Dies and Perforation Tools
- LOT-SKT embossing printing plates
- Film orientation system components
- Machine-compatible carriers and mounting brackets.
Her proje, ürün numunesine, CAD datasına ya da mevcut kalıp üzerinden tersine mühendislik ile hazırlanır. Üretim toleranslarımız ±0.01 mm hassasiyetle işlenir. Tüm kalıplar, 5 eksenli CNC tezgâhlarında işlenir, yüzey sertleştirme ve taşlama işlemleri sonrası %100 kalite kontrolü yapılır. Talep edilirse test blisterleri ile uyumluluk raporu sağlanır.
⚙️ Main Components and Technical Definitions of Format Templates
The format sets we produce for blister and strip machines consist of the following main components:
- Lower Mold (Cavity Plate)
- It is the part that shapes the blister packs in which the product will sit.
- In alu-alu systems, cold forming (deep-draw) is used, while in alu-PVC systems, thermoforming is performed.
- Material: 1.2312, 1.2379 or 7075-T6 aluminum
- Tolerance: ±0.01 mm
- Covering: PTFE, nitriding, anodizing (optional)
- Production Technique: CNC milling, surface grinding, and form grinding create a perfectly matching geometry.
- Corrosion Resistance: Surfaces suitable for > 300-hour salt spray testing.
2. Upper Mold / Sealing Plate
- It is a printing plate that enables the film layer to be sealed in a blister pack.
- It works integrated with PID-controlled heating systems.
- Material: D2 steel or special alloy surface
- Surface Option: Plain, textured, line-printed
- Heat Distribution: 130–230 °C adjustable regional temperature control
- Heat Transfer Efficiency: %90’ın üzerinde iletim sağlayan bakır-çelik hibrit gövde opsiyonu
3. Cutting Die (Punch / Perforation Tool)
- It allows the blister pack to be separated into single or multiple dose forms.
- It features high-hardness ground cutting edges.
- Material: 1.2379 steel, HRC 58–60
- Cutting Tolerance: ±0.02 mm
- Cutting Type: Straight, circular, and wavy edge options.
- Abrasion Resistance: 1 million stroke service life (average)
- Operation without lubrication for low friction surfaces
4. Embossing Tool
- It allows production information such as LOT, expiry date, and batch number to be embossed onto the blister pack.
- Structure: Modular lettering / Positive-negative character system
- Integration: It can be mounted integrated with the upper mold or independently.
- Character Size: Within a height range of 1.5 mm – 3 mm
- Material: Hardened engraving steel
5. Film Guide Plates / Guidance Systems
- It ensures that PVC, aluminum, or lamination materials are fed with the correct tension and alignment.
- Material: PTFE-coated slide systems or low-friction bearings
- Voltage Adjustment: Spring tension or servo-controlled tensioning system.
- Feature: Static electricity discharge (antistatic) brush or rod integration.
6. Support Plate / Format Carrier
- It is the main carrier platform on which the mold sets are mounted to the machine.
- Structure: C45 steel chassis + stainless steel connecting surfaces
- Transition System: Quick-change compatible locking mechanisms.
- Assembly Time: Format transition time: < 10 minutes (with an experienced operator)
🔍 Formatting Sets According to Packaging Material
◾ Alu-Alu Format Sets
- Deep drawing die (cold-form)
- It minimizes the products' exposure to moisture, light, and oxygen.
- It is particularly preferred for antibiotics and photosensitive drugs.
- Cold forming pressure: 8–12 tons
- Aluminum thickness tolerance: Compatible with ±0.01 mm.
◾ Alu-PVC / Alu-PVDC Format Sets
- Thermoforming molds
- Large-volume, economical, and transparent blister solution.
- Used in OTC and supplement products.
- Vacuum suction force: Supported down to -0.7 bar.
- PID controlled resistance group option
◾ OPA-Alu and Alu-PET Format Teams
- Special surface geometry for multilayer barrier materials.
- Design and print control to prevent lamination delamination.
- Layer thickness accuracy: Control between 30–80 microns
◾ Strip Packaging Molds
- The products are sealed tightly between two layers of film.
- Flat or circular cutting dies, quick-change mechanisms.
- For single-dose forms such as tablets, minitablets, and powder products.
- Heat pressing temperature: Between 150–200 °C
- Cutting tool life: Tested for up to 1.5 million keystrokes.
🎯 Why Choose Our Format Teams?
- ✅ Manufactured with ±0.01 mm accuracy (using CNC)
- ✅ GMP compliant materials and surface treatments (stainless steel interface, corrosive resistance, anti-stick coating)
- ✅ Fast delivery and custom manufacturing with CAD/CAM support.
- ✅ 3D scanning (reverse engineering) and compatible CAD design for remanufacturing from old molds.
- ✅ Makine markasına göre %100 montaj uyumu ve test garantisi
- ✅ Quick-Change design that minimizes format change time and operator training support.
- All molds are custom-designed to your product form, production speed, and packaging material, and delivered ready for assembly., We can provide all formatting solutions on a turnkey basis.