Choosing the right secondary packaging machine: a comprehensive guide

Secondary packaging is a vital aspect of the pharmaceutical industry, ensuring products are properly grouped, protected, and labeled for regulatory compliance. With the variety of secondary packaging machines available today, selecting the best option for your operation can be challenging. This guide will explore the different secondary packaging machine types, their applications, and key factors to consider when choosing one.

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Understanding secondary packaging machines

Secondary packaging machines are designed to package products that have already been enclosed in primary packaging. In pharmaceutical manufacturing, secondary packaging serves to group products, protect them from environmental factors, and ensure they are labeled and prepared for distribution. These machines improve safety, compliance, and overall packaging efficiency.

Secondary packaging machine types

To meet the diverse needs of pharmaceutical packaging, several secondary packaging machine types are available. Here’s a detailed look at the most prominent types:

Shuttle machines

Shuttle-type medical and pharmaceutical sealing machines are ideal for cold seal applications. They are perfect for handling fold-over cards and wallet-style packaging designs. These machines offer a medium-sized sealing area (14” x 18”). They also provide process controls for validation and a validation port for direct device connections. Some types of shuttle machines offer remote access via Ethernet or optional Wi-Fi as well. This includes a USB connection for cycle history downloads. Shuttle machines are a great choice for medium-sized production runs where precision and control are key.

Rotary machines

Rotary machines, such as the six-station rotary medical sealing machine, are designed for cold seal applications. They excel in efficiently processing fold-over cards and wallet-style packaging. With a spacious sealing area (18” x 24”),these machines accommodate a wide range of package sizes. They also come with integrated process controls for validation. Some types of rotaries can be accessed remotely via Ethernet. They offer additional integration capabilities for feeding systems and unloading finished packages. Rotary machines are ideal for high-efficiency operations and larger batch sizes.

Inline equipment

Inline medical and pharmaceutical sealing machines are specifically designed for cold seal applications. They feature a precision indexing inline conveyor, ensuring perfect alignment of the sealing fixture with the relieved faceplate. These secondary packaging machines offer a generous sealing area (14” x 28”), making them highly versatile for different package sizes. Inline machines can integrate feeders for cards, lidding, or blisters and can be automated to unload finished packages. This setup is highly flexible and can scale with your operation’s needs.

Carousel equipment

The fully automatic carousel blister sealing machine is designed for high-volume blister packaging. It boasts fourteen stations and a sealing area of 18” x 24”, making it perfect for large-scale packaging requirements. Features include an automatic card feeder, blister feeder, and finished package unloader. It also features eight open stations that allow for product loading or the integration of custom automation solutions. Carousel secondary packaging equipment is a heavy-duty, industrial-grade machine that provides reliability and efficiency for high-volume production.

Cartoning machines

Cartoning machines are used to erect, fill, and close cartons. This makes them ideal for packaging blister packs, bottles, or tubes into cartons. Depending on your needs, cartoning machines can be horizontal or vertical. For high-speed applications, continuous motion cartoners can increase throughput without sacrificing quality.

Case packers

Case packers are designed to pack products into trays or cases. This is a versatile secondary packaging machine, because it can handle various packaging configurations such as wraparound or pick-and-place options. They ensure products are securely packed, ready for transport or storage.

Shrink wrapping machines

Shrink wrapping machines apply a protective film around products, which is then heated to shrink tightly around them. This creates tamper-evident packaging and provides additional product protection during shipping.

Labeling machines

Labeling machines are very important in the pharmaceutical sector to ensure compliance with regulatory standards. They can apply barcode labels, tamper-evident labels, and other types to maintain product traceability. Print-and-apply systems help streamline this process for high-volume packaging.

Palletizing machines

Palletizing machines automate the process of stacking finished packages onto pallets. Robotic palletizers are highly adaptable, handling various package sizes and configurations while ensuring stability during transport.

Tray erectors

Tray erectors create trays from flat cardboard blanks and are used to package products that need added protection or presentation. They are ideal for operations that require secure packaging for multiple units.

Key considerations when choosing secondary packaging equipment

Selecting the right secondary packaging machine depends on your specific production needs. Here are some key factors to consider:

•        Product type and size: the nature of your products will largely determine which machine is most suitable. Fragile products may require gentler handling, while bulky items need more robust solutions. Machines like gentle handling case packers minimize the risk of product damage.

•        Production speed and capacity: your operation’s output requirements will dictate whether you need a high-speed solution, such as rotary machines or high-speed cartoners, or a slower machine for small-batch production.

•        Flexibility and versatility: choose machines that can handle a variety of packaging styles and sizes. Examples are modular systems that can adapt to different product lines as needed.

•        Automation level: decide whether full automation is necessary. Fully automated machines, like carousel blister sealers, can significantly increase throughput. Yet they may come with higher upfront costs.

•        Compliance and safety: ensure the machine meets GMP, FDA, and other regulatory standards. Machines with process control features and validation ports help ensure regulatory compliance.

•        Space and layout: evaluate how much space you have available for the machine. Compact machines like shuttle-type sealers are ideal for medium-sized production facilities. On the other hand, larger setups like carousel equipment require more floor space.

The benefits of investing in advanced secondary packaging machines

Investing in advanced secondary packaging machines offers several key advantages:

•        Efficiency: automated machines like robotic palletizers and integrated cartoners speed up production by reducing manual labor.

•        Product safety: machines designed for pharmaceutical applications ensure product safety by offering tamper-evident sealing and protective packaging.

•        Cost savings: although the upfront cost may be high, advanced machines often result in long-term savings through reduced labor costs and increased throughput.

•        Regulatory compliance: built-in validation and process control features help ensure that packaging meets the stringent requirements of the pharmaceutical industry.

•        Sustainability: some packaging machines are designed to minimize material usage, reducing waste and environmental impact.

Secondary packaging machine solutions

Choosing the right secondary packaging machine, but also secondary packaging equipment partner, is a critical decision. One that can significantly impact your packaging efficiency, product safety, and regulatory compliance. Understand the different types of machines available and consider factors such as product type, production speed, and automation levels. This way you can select a solution that best fits your operation.

To explore the latest secondary packaging solutions and find the best fit for your business, reach out to our team for a consultation. Or you can request a sample to see how our advanced machines can elevate your packaging process.

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