Schubert-Pharma was commissioned to develop a more efficient packaging process that would guarantee the manufacturer faster format changes and lower material costs.
The customer, a renowned filler of ampoules and vials, wanted to thermoform plastic trays directly from the roll. The benefits speak for themselves: the company saves on material and logistics costs and achieves greater efficiency in the packaging process.
With the previous laborious format change, the customer had to place the pre-formed plastic trays in a warehouse and unpack them for the packaging process. The use of prefabricated trays required the customer to accept increased material consumption and logistical costs. Schubert-Pharma was brought in to solve this problem.
Solution
Thermoforming, filling and wrapping
The customised line designed by Schubert-Pharma for the customer separates the thermoforming machine from the filling and cartoning process. The packaging line is capable of packaging both ampoules (standing in trays) and ampoules (flat in locking trays). The wide range of formats that can be used is remarkable. The customised line packs small packages, e.g. five vials or ampoules, in one blister/carton and processes ten blisters with five products each per carton.
With this machine, Schubert-Pharma has provided the filler with a system that will continue to rationalise packaging for many years to come.
Technical details
Thermoforming machine
In the thermoforming unit, the blisters are shaped and perforated. A shaped cap is used in the thermoforming process. The 400 mm wide film sheet runs continuously at a speed of up to 9 metres per minute. Punching is performed by ultrasound; a process that allows any desired punch profile to be achieved and guarantees low-cost tools with a fast changeover. The thermoforming and punching units automatically adapt to the speed of the film. The entire machine is programmed by entering the parameters on the operator interface panel.

Filling and wrapping process
The blisters are then prepared for loading. At the same time, the products (vials or ampoules) are fed into the machine and grouped. The loaded blisters are placed in a pre-erected top-loading box and closed once the package leaflet has been added. After marking with ink-jet printers, the individual boxes pass to the transport logistics.

Overall performance
- Thermoforming machine decoupled from the filling and cartoning process
- Range of formats for small packages: e.g. five ampoules or ampoules packed in one blister/carton, up to ten blisters with five products each processed per carton
- Online thermoforming significantly reduces material consumption
- Packaging can also be rationalised in the future