Solutions

We have a solution for everything – and more importantly: they can all be connected through our unique Körber Ecosystem. In our current seven areas of expertise, we are at your disposal with our comprehensive know-how.

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Software solutions

Software solutions

With our PAS-X MES - on premise or cloud-based - and our software solutions for analysis, track & trace, networked factories, and intelligent packaging, we are the world's leading supplier and partner to the pharmaceutical and biotech industries. With our holistic understanding and use of digitalization, you remain future-proof and combine digital innovation with sustainability.

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Handling systems

Handling systems

Looking for perfectly designed production lines that reduce operational complexity, can adapt quickly to changes in the pharmaceutical industry and work seamlessly with your software and machinery? We are specialists for complete handling systems for pharmaceutical and medical products. Our solutions are decisive in the field of contactless and safe transport of e.g. glass syringes.

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Inspection machines

Inspection

As the world's leading inspection expert, we develop solutions for the pharmaceutical and biotech industries. Our range of products extends from AI-supported, high-performance machines and semi-automatic machines to laboratory units and inspection applications for in-process control. As thought leaders in the field, we always make sure that machines and software speak the same language.

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Machine finder

Packaging machines

Packaging machines

We are a leading supplier of packaging machines for liquid and solid pharmaceutical and medical products. With our blister, sachet and stick packaging machines we offer solutions for primary packaging. Our side and topload cartoners set standards worldwide for secondary packaging. Our ecosystem approach ensures that all machines, software, and other components operate harmoniously and perform at the highest level.

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K.Pak Topload Case Packer

Introducing our latest solution from Körber; the K.Pak Topload Case Packer! Created specifically for the pharmaceutical industry, the K.Pak solution provides operator-friendly machines to complete any production line. Our solution focuses on innovative technology, high-quality design and expert handling and packaging of your product. It’s time to start connecting the dots with Körber!

Packaging solutions

Packaging solutions

As long-standing specialists, we develop packaging solutions for innovative and high-quality secondary pharmaceutical packaging made of cardboard. We offer you solutions for counterfeit protection, standard folding boxes and much more.

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Consulting

Consulting

Our experts will advise you during the analysis of your requirements, show you optimization potential and support you during the implementation of projects in all areas of the pharmaceutical, biotech and medical device industry. Our aim is to achieve holistic optimization for your factory of excellence.

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Services

Services

You need help with a specific product or have questions about one of our areas of expertise? Körber is your forward-looking navigator to excellence. We provide data-led, proactive advice and services to improve what is needed to scale and evolve towards your factory of excellence.

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Blister packaging

What is blister packaging?

Blister packaging is a widely used method in the pharmaceutical industry, designed to protect individual doses of medication from external factors such as moisture, light, and contamination. It consists of a plastic cavity, usually made from materials like PVC (polyvinyl chloride) or PET (polyethylene terephthalate), which securely holds the pharmaceutical product. The cavity is then sealed with aluminum foil or other protective materials through a heat-sealing process.

This packaging method is commonly used for tablets and capsules, offering advantages such as dose accuracy, tamper resistance, and extended shelf life. It ensures medication integrity and helps patients follow their treatment regimens correctly.

How does a blister packaging machine work?

A blister packaging machine automates the process of forming, filling, and sealing blister packs. The process consists of several key stages:

First, a plastic film or aluminum sheet is heated and molded into cavities using either thermoforming (heat-based shaping) or cold forming (pressing aluminum into shape). Once the blisters are formed, pharmaceutical products such as tablets or capsules are placed into the cavities through an automated filling system. After this, a lidding material, typically aluminum foil, is applied and heat-sealed to create an airtight, tamper-resistant pack.

The final step involves cutting and perforation, where the blister packs are trimmed into their final shape. Advanced automated visual inspection (AVI) systems ensure each pack meets pharmaceutical quality standards, detecting any defects before distribution.

Blister packaging machines come in semi-automatic and fully automatic models, depending on production requirements.

Applications of blister packaging in pharmaceuticals

Blister packaging plays a crucial role in pharmaceutical manufacturing by ensuring product safety and quality throughout the supply chain. It is primarily used for oral solid doses, including tablets, capsules, and soft gels. Additionally, it is applied to parenteral products, such as pre-filled syringes and vials, and for medical devices, including diagnostic kits and lancets.

One of its most significant applications is in medication adherence programs, where blister packs help patients track their dosage schedules. Pharmaceutical companies also rely on blister packaging for serialization and anti-counterfeiting measures, ensuring regulatory compliance and supply chain integrity.

Benefits of blister packaging in pharmaceuticals

Blister packaging provides multiple benefits that make it a preferred choice for pharmaceutical products:

  1. Product Protection: By shielding medications from moisture, oxygen, and UV light, blister packaging extends shelf life and maintains drug potency.
  2. Tamper Resistance & Patient Safety: Sealed blister packs prevent unauthorized access, ensuring that the medication is uncompromised and safe for consumption.
  3. Dose Accuracy & Compliance: Each pre-measured dose in an individual cavity helps patients follow their prescriptions correctly, reducing the risk of missed or double doses.
  4. Cost-Effective & Efficient Production: Automated blister packaging machines improve manufacturing efficiency by reducing material waste and labor costs.
  5. Customizable & Versatile: Blister packs can be designed in various shapes and sizes, accommodating different medications and branding needs.

Types of blister packaging

Blister packaging varies based on materials and sealing methods, with three primary types used in the pharmaceutical industry:

  1. Thermoformed blister packaging: This method involves heating a plastic film and molding it into cavities. The formed blisters are then sealed with aluminum foil or other lidding materials. It is the most common method for tablets and capsules.
  2. Cold formed blister packaging: Instead of plastic, aluminum laminate is used to create the cavities. Cold forming provides superior protection against moisture and light, making it ideal for moisture-sensitive drugs.
  3. Compliance packaging: Compliance blister packs include calendar designs or smart tracking features, ensuring patients adhere to prescribed treatment schedules.

Additionally, child-resistant and senior-friendly designs are available to enhance safety and accessibility.

Regulatory compliance and quality standards in blister packaging

Pharmaceutical packaging is subject to strict global regulations to ensure product safety, efficacy, and patient adherence. Blister packaging must comply with various Good Manufacturing Practices (GMP) and packaging guidelines established by regulatory agencies worldwide.

  1. FDA regulations: In the United States, the Food and Drug Administration (FDA) oversees pharmaceutical packaging requirements. Title 21 CFR outlines specific guidelines for packaging, labeling, and stability testing to ensure product safety.
  2. European Medicines Agency (EMA) compliance: The EMA’s guidance on pharmaceutical packaging focuses on tamper resistance, serialization, and material compatibility to enhance patient safety and trackability.
  3. WHO packaging standards: The World Health Organization (WHO) provides recommendations on global pharmaceutical packaging best practices, ensuring medication integrity across different climates and markets.
  4. Serialization and Track & Trace regulations: To combat counterfeit drugs, track-and-trace technologies and serialization requirements are enforced worldwide. These include:
    • The U.S. Drug Supply Chain Security Act (DSCSA)
    • The European Falsified Medicines Directive (FMD)
    • Global GS1 Standards for pharmaceutical packaging

Future trends in blister packaging

The future of blister packaging is driven by innovations in technology and sustainability. Several trends are shaping the next generation of pharmaceutical packaging:

Smart blister packaging: The integration of QR codes, NFC (Near Field Communication), and RFID tags enables real-time tracking and patient adherence monitoring.

Eco-friendly materials: With the growing demand for sustainable packaging, companies are developing biodegradable plastics and paper-based blister packs to reduce environmental impact.

Automation & AI integration: Advanced robotic blister packaging machines are improving efficiency, while AI-driven quality control systems detect defects with greater precision.

Regulatory compliance & serialization: Pharmaceutical companies are adopting advanced anti-counterfeiting measures, such as blockchain-based traceability, to comply with global regulations.

These advancements are shaping a more efficient, sustainable, and secure blister packaging landscape.

Key takeaways

  • Blister packaging is a protective and efficient packaging method used for pharmaceutical products.
  • Blister packaging machines form, fill, seal, and cut plastic or aluminum-based blister packs.
  • It enhances shelf life, tamper resistance, and medication adherence while ensuring dose accuracy.
  • Global regulations, serialization, and smart packaging innovations are shaping the future of blister packaging.
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