The Problem
A pharmaceutical manufacturer faced a growing bottleneck. Their blister packaging machine ran smoothly, but after the blisters exited, everything slowed down. Operators collected blisters by hand, inserted them into cartons with leaflets, and closed the flaps — all manually. As orders increased, the semi-automatic cartoning process couldn't keep up. Hiring more workers wasn't a long-term answer. Automation was.
The Product
The product was a standard tablet blister pack — PVC and aluminum foil, 75 × 45 × 5 mm. Each carton held one or two blisters, plus a folded patient information leaflet. The carton style was straight tuck end. The target speed was 120 cartons per minute, with the ability to switch between one-blister and two-blister formats quickly.
The Challenges
Four key issues needed solving. First, lightweight blisters tended to shift during high-speed transfer, risking misalignment. Second, leaflet insertion had to be flawless — pharmaceutical regulations demand zero missing leaflets. Third, format changeover between SKUs had to be fast. Fourth, everything needed GMP-compliant stainless steel construction.
The Solution: DZH-150 Cartoning Machine
Haizhong recommended the DZH-150 intermittent-motion cartoning machine. Its step-by-step operation ensures precise handling at every station — carton picking, opening, product insertion, leaflet insertion, and tuck closing.
The servo-driven product pusher handles both one-blister and two-blister cartons with programmable stroke control, eliminating the shifting problem. The integrated leaflet unit picks from a magazine, verifies each leaflet via sensor, and stops automatically if one is missing. Format changeover takes about 15 minutes — parameters are saved as recipes on the HMI touchscreen. Full stainless steel construction meets GMP requirements, and transparent guarding allows complete process visibility.
The Result
The DZH-150 was installed downstream of the existing blister machine. Blisters now flow automatically from stamping to cartoning to finished carton discharge — no manual handling. The line runs consistently at 120 cartons per minute, doubling previous capacity. Operators have been redeployed to quality inspection and supervision. Rejected cartons dropped measurably within the first quarter.
Haizhong engineers provided three days of on-site commissioning and training, plus full documentation. When the client later needed to add inline batch coding, our team supported the integration remotely.
The Takeaway
Cartoning is often the hidden bottleneck in pharmaceutical packaging. Companies invest in high-speed upstream equipment but overlook the final step. Automating cartoning with a machine like the DZH-150 turns the end of the line from a constraint into a strength — matching upstream speed, ensuring compliance, and scaling with the business.
Is Your Line Ready?
If your blister machine runs fast but your cartoning lags behind, it may be time to upgrade. Contact Haizhong Machinery with your product samples and targets. We'll provide a tailored proposal and demonstration video.
Zhejiang Haizhong Machinery Co., Ltd.
Wenzhou, Zhejiang, China
Innovation-Driven. Service-First. Trusted Worldwide.
