Pharmaceutical packaging is primarily based on two critical factors: patient safety and ease of use. In addition, several other elements such as child resistance, tamper-proof sealing, and long shelf life also play an important role. Together, these factors determine the overall success of pharmaceutical packaging.
Most daily-use medicines are manufactured in pill or capsule form. For example, paracetamols, antacids, painkillers, and other oral drugs are commonly pressed into tablets and stored in first-aid kits for emergency use. Therefore, these medicines require strong and reliable packaging to protect them from moisture, contamination, temperature variations, and long-term degradation.
Considering all these requirements, only two packaging formats are widely used for pills and capsules: strip packaging and blister packaging.
Understanding Blister and Strip Packaging
Although both blister and strip packaging are used for unit-dose medicines, their structures and applications differ significantly.
Blister Packaging
In blister packaging, tablets or capsules are placed inside pre-formed, malleable but impermeable cavities called blisters. These cavities are then sealed using aluminum foil or paper-based lidding material.
Typically, blister cavities are formed using polymer materials such as PVC through thermoforming or cold-forming processes. As a result, blister packs offer strong physical protection and good visibility of the product.
Strip Packaging
Strip packaging, on the other hand, uses two layers of heat-sealable film to enclose tablets. In most cases, this film is made of aluminum, commonly known as alu-alu packaging. Sometimes, the foil is laminated with polymer material for additional strength.
Unlike blister packs, strip packs do not have pre-formed cavities. Instead, the tablets are sealed directly between two layers of foil, fully enclosing each unit.
Manufacturing Process of Blister and Strip Packaging
Although both formats provide individual containment, their production processes differ.
Blister Packaging Process
Blister packaging follows the form-fill-seal method, where forming, filling, and sealing occur on the same machine.
First, cavities are formed using heat or pressure. Next, tablets are placed into the cavities automatically. Then, the lidding material is applied and heat-sealed. Finally, the blister cards are cut into individual packs.
As a result, the entire process remains fast, consistent, and highly automated.
Strip Packaging Process
In strip packaging, two flexible films pass through a sealing press. Meanwhile, tablets are dropped between the films at precise intervals.
After that, the films are sealed together to form individual pockets. Subsequently, these pockets are cut into dosage strips and packed into cartons.
Although effective, this process involves more individual handling of tablets.
Which Packaging Method Is Faster?
When comparing speed and productivity, blister packaging has a clear advantage.
In strip packaging, tablets are dropped one by one into film pockets. Consequently, sealing and cutting take more time. In contrast, blister machines place multiple tablets simultaneously into pre-formed cavities and seal them within milliseconds.
Therefore, for manufacturers requiring continuous high-volume supply, blister packaging is generally more time-efficient and cost-effective.
Challenges in Blister and Strip Packaging
Like any industrial process, both packaging methods have their challenges.
In blister packaging, most issues arise from incorrect calculations or human error. For instance, improperly sized cavities may reduce sealing quality and cause tablets to crack. However, with modern automated machines and reduced manual handling, such risks are now minimal.
Strip packaging mainly faces design-related limitations. Since foil is used on both sides, the package tightly wraps around the tablet. As a result, even minor mechanical impacts may cause perforation. Moreover, trapped heated air during sealing can weaken the film.
In comparison, blister packs with pre-formed cavities remain more resistant to such damage.
Advantages of Blister and Strip Packaging
Both packaging formats offer distinct benefits depending on the application.
Advantages of Blister Packaging
Blister packs provide strong protection against environmental contamination. Additionally, they are easy to use, as tablets can be accessed by pushing or peeling the seal.
Because blister packs use semi-rigid materials such as PVC and aluminum laminates, they offer better resistance to mechanical stress. Therefore, even rough handling during transportation rarely affects the product inside.
Advantages of Strip Packaging
Strip packaging is particularly suitable for capsule-based medicines. Since the foil wraps tightly around each unit, moisture and air penetration is minimized.
Furthermore, strip packs keep capsules separated and organized, preventing them from sticking together. In addition, they require more force to open, making them relatively more child-resistant.
Role of Automation in Modern Packaging
Today, both blister and strip packaging machines are designed with minimal human intervention. As technology advances, machines are programmed to identify and eliminate potential errors.
Moreover, modern pharma packaging lines integrate inspection systems, automation controls, and quality validation processes. Consequently, both blister and strip packaging methods can now achieve higher efficiency, accuracy, and reliability.
Conclusion
Although strip and blister packaging differ in structure and processing methods, both play important roles in pharmaceutical manufacturing.
Blister packaging offers higher speed, stronger protection, and better handling characteristics. Meanwhile, strip packaging remains useful for moisture-sensitive and capsule-based medicines.
Therefore, the choice between the two depends on product requirements, production volume, and regulatory needs.
If you need assistance in evaluating your pharmaceutical packaging facility or upgrading your blister and strip packaging systems, Accupack Engineering can help you improve efficiency, compliance, and long-term performance.
