The Challenge of Angular Geometry in Blister Packaging
In the pharmaceutical and nutraceutical sectors, distinctive tablet shapes are increasingly popular for brand recognition. However, transitioning from standard round tablets to geometric shapes—such as squares—presents a significant engineering hurdle for blister packaging lines.
Unlike round tablets that flow naturally, square tablets possess sharp corners and flat edges. In conventional feeding channels, they are highly susceptible to “bridging” (where tablets interlock and block the pathway) or jamming. Furthermore, if the edge thickness (band thickness) of the square tablet is relatively thin, the tablets can easily overlap, flip, or experience “twinning” (two tablets entering a single chute or cavity), leading to high rejection rates and machine downtime.
The Jornen Solution: Custom Vibratory Blister Feeder
To address these geometric constraints, our engineering team recently designed and tested a customized Vibratory Blister Feeder, specifically tailored for a client’s square tablet product.
As shown in our recent Factory Acceptance Test (FAT), the system uses a carefully calibrated vibratory bowl to manage tablet flow and orientation.
Key Technical Highlights:
* Custom-Tooled Vibratory Tracks: The internal tracks of the vibratory bowl were precisely machined to match the exact dimensions and edge thickness of the square tablets. This selective tooling ensures that only tablets lying in the correct orientation can ascend the track, automatically rejecting and recirculating those that are standing on edge or overlapping.
* Precision Vertical Chutes: Once oriented, the tablets are discharged into vertical feeding chutes. The clearances within these chutes are engineered to tight tolerances. They are wide enough to let the square corners slide freely without friction, yet narrow enough to prevent the tablets from tilting or flipping during descent.
* Synchronized Deposition: The feeder is perfectly synchronized with the indexing web of the blister machine. The square tablets are deposited into the formed cavities with high precision.
FAT Results: Smooth and Jam-Free Operation
During the FAT trial run, the vibratory feeder achieved a continuous, jam-free flow. The square tablets aligned effortlessly and populated the simulated blister web at optimal production speeds. The successful trial validated the feeder’s design, proving it can handle difficult tablet shapes with the same reliability as standard round pills.
Conclusion
In some cases, packaging non-standard solid dosages doesn’t have to mean compromising on speed or efficiency. With targeted engineering and precise tooling, Jornen’s vibratory feeding systems can adapt to virtually any product geometry.
Watch the full FAT trial run on our YouTube channel:
https://youtu.be/1QW4rCdNunY