Automatic Packaging Production Line for Ampoule Bottles

1.1 Blister Packaging
The blister packaging section processes PVC rigid sheets into blister trays online. Bottles are fed from the connected labeling machine, and straws are automatically inserted into the trays first. The system then automatically supplies bottles and places them into the formed trays accurately. After bottle loading, online detection is performed to verify correct placement. The trays go through punching and cutting, and unqualified products are automatically rejected. Qualified blister trays are positioned and delivered to the cartoning station, ready for the next packaging process. The whole section is equipped with material level detection and alarm functions for PVC and PTP films as well as bottles. It also provides detection and rejection control for bottle loading, feeding detection and safety shutdown for punching, and position detection for tray output, ensuring stable and reliable blister forming and filling.
1.2 Cartoning Packaging
The cartoning packaging process starts with tray feeding and conveying. The system inspects whether bottles are correctly loaded in the trays. Manual loading of leaflets and cartons is supported; the machine automatically folds leaflets (supports 1–4 folds) and transports them to the cartoning position. Cartons are automatically picked, opened, and transferred forward. Leaflets and loaded blister trays are inserted into cartons simultaneously. Optional mechanical batch coding is available to print three rows of batch numbers with high precision. The cartons then go through flap folding, tongue inserting, and sealing. Unqualified cartons are detected and rejected automatically, and qualified finished products are discharged smoothly. The cartoning system is equipped with material level detection and alarm for leaflets and cartons, feeding detection for blister trays, and real-time monitoring and control for leaflet and tray conveying. It also features overload detection to prevent jamming, with alarm and automatic shutdown functions. Cartoning quality inspection and automatic rejection ensure that only qualified products enter the final output, realizing fully automatic, stable and reliable cartoning packaging.

2.Blister Tray Forming, Bottle Insertion & Cartoning Machine
This integrated unit completes tray making, bottle loading, leaflet inserting, and carton sealing.
Stable output: 40–55 cartons per minute
Suitable for 1 ml, 2 ml, 5 ml, 10 ml ampoules
The tray forming section uses positive-pressure blowing for full and uniform blisters. A four-axis servo-driven loading manipulator ensures stable, accurate, and smooth bottle insertion. The transfer system conveys qualified trays steadily to the cartoning section.
The cartoning unit automatically folds leaflets (1–4 folds), opens cartons, pushes trays and leaflets into boxes, and seals cartons. It supports batch coding with positioning error less than ±1.5 mm. The whole process is monitored by photoelectric sensors; empty trays, missing leaflets, and empty boxes are automatically rejected.

3.Control & Safety System
The entire line is controlled by a PLC and touch screen system with three-level authority management. It features:
Fully automatic, semi-automatic, and inching modes
Real-time production monitoring and fault alarm
Automatic stop for material shortage or overload
Interlocked operation between stations
Multiple emergency stop switches and safety doors
Full enclosure and rounded edges for operator safety
After power failure, the line remains stopped and requires manual restart.

4.Technical Features
This integrated blister packaging and cartoning machine realizes a full automation process, including bottle feeding, tray forming, tray punching, automatic bottle loading into trays, carton unfolding, leaflet folding, tray and leaflet cartoning, and carton sealing.
Alarm devices are installed for all packaging material storage bins to monitor material levels. The machine is equipped with fault stop protection that displays fault causes and locations in real time. A well‑designed buffer system minimizes downtime and allows continuous production even when other equipment stops, greatly improving the efficiency of the entire production line.
The machine is equipped with an advanced computer control system that supports production counting, equipment status monitoring, fault troubleshooting guidance, and material shortage detection. It automatically alarms and shuts down in emergency conditions to ensure safe and accurate operation.
Mechanical or visual detection is adopted to check the presence of bottles, and unqualified products are automatically rejected. Movable collection devices are provided at each rejection point. Isolation structures are used during packaging to prevent product contamination and damage. The transmission area and packaging area are completely separated, making the structure compact, adjustment convenient, cleaning fast, and maintenance easy. The design fully meets GMP standards.
The machine achieves a high degree of automation: PVC forming, blister punching, automatic tray transfer, oral liquid bottle loading, automatic leaflet inserting, and automatic carton sealing. Leaflets are folded automatically, and the machine can connect seamlessly with the upstream labeling machine. All monitoring points are controlled automatically; running status is shown on the display in real time, and the machine stops automatically with clear fault location and cause displayed on the touch screen.
The electrical configuration is high‑end, with more than 90% of electrical components imported from well‑known international brands.
Integrating tray forming, bottle loading, and cartoning in one unit, the machine features a compact structure and simple operation. It is controlled by a programmable logic controller (PLC) with a touch‑screen human‑machine interface. Molds can be customized according to customer requirements.

5.Conclusion
This automatic ampoule bottle packaging line achieves high speed, high precision, high stability, and full automation. It reduces labor, lowers breakage rates, improves production efficiency, and fully meets pharmaceutical packaging standards. It is suitable for mass and stable production of oral liquids and similar small round bottles.