How to choose a blister packaging machine

Choose a blister packaging machine in six steps: seal type, volume, pack format, validation, automation and total cost of ownership.

Heat seal and cold seal machines

From manual shuttle to automatic inline

Validation features for pharma

Installation and ongoing support

Tell us about your packaging job and we will help you match it to the right machine. Get in touch.

The short answer

Start with the pack, not the machine. First decide whether your pack is heat sealed or cold sealed. Then match the machine type to your volume: shuttle machines for low to medium volumes or limited floor space, rotary machines with 4, 6 or 8 stations for medium to large volumes, and inline or carousel machines with 12, 14 or 16 stations for large production. Check that the sealing area fits your card or wallet format and, for pharmaceutical or medical packs, which validation features you need. Finally, compare the total cost of ownership, not just the purchase price.

Not sure where to start? Contact the team or try the free Quick Scan on our homepage.

1. Heat seal or cold seal?

A heat seal machine seals the pack with heat and pressure. A cold seal machine needs only pressure, no heat, and opens up pack options such as dispenser functions, multi-panel and free-standing packs. Our range includes heat seal machines, cold seal machines and models that run both, and several heat seal rotary models can take an optional press system so they also process cold seal packs.

2. Shuttle, rotary, carousel or inline?

Match the machine type to your volume:

Low to medium volumes or limited floor space: shuttle machines, with a movable sealing tray that slides in and out of the sealing zone. Table top units are also available.
Medium to large volumes: semi-automatic and automatic rotary machines in 4, 6 and 8 station versions. An indexing rotary table lets operators load, seal and unload at the same time.
Large production: inline and carousel machines in 12, 14 and 16 station versions, built for high-volume demand with minimal operator input.

See the full range for pharmaceutical packaging and for retail packaging.

3. Pack format and sealing area

The sealing area determines which card or wallet formats fit the machine, so check it against your pack. For example, the FAB4-1012 has a 10 x 12 in sealing area, the FAB8-1418 14 x 18 in and the CBS/PH30A-1428 14 x 28 in. Larger standard and custom sizes are quoted on request.

Machines are configured for card to card or card to plastic packs, and many models handle fold-over cards and wallet designs. The pharmaceutical shuttle models and selected rotary and inline models also handle medical lidding such as foils, medical paper and Tyvek.

4. Pharmaceutical and medical packs: validation

For regulated packs, check what the machine records and how easily it can be qualified. Depending on the model, our pharmaceutical machines offer process controls for validation with a validation port for direct device connections, on-screen temperature calibration with optional on-screen pressure calibration, a USB connection to download the cycle history, and remote access over Ethernet with optional Wi-Fi. A clean room exhaust filter is available as an option on the SB/PH1-1012.

For a step-by-step view of machine qualification, read our article on IQ, OQ and PQ for blister machines.

5. Automation and options

Automatic feeding reduces labor costs: automatic rotary models are available with automatic blister and card feeders and a finished package unloader. Printing, scanning and vision systems can be integrated, and machines can be reconfigured or extended as your products and volumes change.

6. Total cost of ownership

The purchase price is only one part of the cost. Before you compare quotes, list:

the machine itself, from stock or made to order;
tooling for each pack format;
packaging materials for your seal type;
operator time, which depends on manual or automatic feeding;
energy: cold seal needs no heat;
changeovers between formats;
validation effort for regulated products;
maintenance, spare parts and support.

Prices depend on the configuration. Ask the team for a quotation.

7. How we help you choose

Our blister machines are built by Starview. We help you from selection to a running line: packaging design, machine selection, process integration and ongoing support. We deliver, install and support machines for customers across Europe and beyond. We can also design and manufacture the packaging components, so the pack and the machine are matched from the start.

Frequently asked questions

What is the difference between a heat seal and a cold seal blister machine?

A heat seal machine seals the pack with heat and pressure; a cold seal machine needs only pressure. Some of our models run both.

Which blister machine do I need for low volumes?

A shuttle machine, also when floor space is limited. Table top units are available too.

How many stations does a rotary blister sealing machine have?

Our rotary machines come in 4, 6 and 8 station versions; inline and carousel machines in 12, 14 and 16 station versions.

Can one machine run both heat seal and cold seal packs?

Yes. Some models are built for both, and several heat seal rotary models take an optional press system for cold seal packs.

Do your machines support pharmaceutical validation?

Depending on the model, our pharmaceutical machines have process controls with a validation port, temperature calibration and a cycle history download.