A: Large punch-out (blister plate cutting) is the final cutting step before finished product output of PVC blister packaging. Process introduction: After hook hole mini punch-out, continuous long PVC blister strips are delivered to the large punch-out station. The large cutting die punches the whole blister strip according to preset outer dimension specifications, separating independent finished blister plates from the leftover PVC carrier sheet. After large punch-out cutting, complete standard-sized blister packs are sent to the finished product output conveyor for automatic collection and stacking. The traction mechanism and speed control system coordinate with large punch-out to guarantee accurate cutting size without offset or waste.

A: Mini punch-out is the intermediate punching procedure after heat sealing on blister packaging machines, also known as hook hole punching. Working flow: After PVC blister sheets finish heat sealing and pass quality inspection, the traction system pulls the sealed plate to the mini punch-out station. The punching die cuts standard retail hook holes on the top edge of each finished blister pack. These hook holes allow finished blister products to be hung on supermarket display racks, which is essential for retail commodity packaging. The mini punch-out die can be replaced to customize different hook hole sizes according to client display requirements.

A: Hot sealing (heat sealing) is the sealing process after material feeding, used to seal PVC blisters with backing paper cards to form sealed blister packs. Process flow: After all products are fully loaded into molded PVC blisters, the machine transports the PVC blister sheet with paper backing to the heat sealing station. The heating mold heats the contact surface of PVC blisters and paper cards simultaneously, then applies pressure to bond the two layers tightly by point sealing method. Point heat sealing creates continuous sealed edges around each blister cavity, completely isolating internal packaged items from external air, dust and moisture, realizing dustproof, moisture-proof and anti-falling packaging protection for products. Temperature control sensors are equipped at the heat sealing station to stabilize sealing temperature and prevent PVC over-melting.

A: Material feeding (product feeding) is the step to load packaged goods into molded PVC blisters after blister forming on blister machines. Standard process: Once the PVC sheet completes blister forming and qualified blister cavities are shaped, the automatic feeder accurately conveys packaged parts, pills, hardware or small commodities into each independent blister slot at a stable speed. For irregular, oversized, fragile or special-shaped materials that cannot be automatically arranged, the blister packaging machine reserves a manual feeding station, allowing workers to manually place products into PVC blisters flexibly, which adapts to diversified packaging production demands. Camera vision inspection can also be matched with the feeding station to check missing feeding.

A: Blister forming is the key molding process for PVC plastic sheets on blister packing machinery, adopting cam-driven positive pressure forming structure. Working principle: The upper forming mold is fixed, the cam drives the lower mold to rise to the upper limit position, tightly compressing the preheated softened PVC plastic sheet. Then the air control valve opens automatically, filtered and pressure-regulated compressed air flows into the inner cavity of the lower mold. Under stable positive air pressure, the PVC sheet fully fits the mold cavity to form customized blister cavities matching product shapes. This blister forming technology ensures consistent blister depth, smooth surface and uniform wall thickness of PVC blisters.

A: PVC preheating is the initial heating procedure of the full automatic blister pack machine, which directly determines the blister forming quality of PVC plastic sheets. Operation steps: After starting the blister packaging machine, the equipment enters the heating standby state first, then the upper and lower heating plates automatically close. The PVC plastic raw sheet is clamped between two heating plates for uniform preheating to soften the PVC material. After finishing preheating, the traction mechanism pulls the softened PVC sheet forward and sends it into the blister forming mold for the next forming process. Proper PVC preheating avoids blister cracking, uneven forming and wrinkling defects during subsequent blister molding.

Q1: Why can’t the cartoning machine start normally?

A: Fault Cause
The most frequent trigger is the unreleased emergency stop button on the control panel.
Solution
Turn and reset the emergency stop button to unlock the safety interlock, then restart the equipment.

Q2: Why does the suction cup fail to pick up cartons (carton cannot be sucked down)?

There are six typical root causes and corresponding fixes as below:

1.Pneumatic pipeline blockage or air leakage
Check the entire air piping circuit, fasten loose joints and repair leaking tubes to stabilize air supply.
2.Aging & hardened suction cup
Replace worn, stiff suction cups with brand-new spare suction cups.
3.Misaligned carton stacking rack position
Readjust the installation position of carton storage rack to match carton size.
4.Carton jam or deformed carton blank
Loosen stacked stuck cartons or replace warped, defective carton raw materials.
5.Insufficient air source pressure
Inspect the air compressor and air pressure gauge to ensure working pressure meets machine standard.
6.Incorrect suction on/off timing parameter
Re-calibrate the suction start and cut-off timing values on the PLC touch screen.

1. Capsule Misalignment & Feeding Issues: Causes & Solutions

Problem 1: Improper Adjustment of the Capsule Feeding Platform
Symptoms
During the capsule feeding and separating step, empty capsules may shift sideways, jam in the guide rails, or fail to seat properly in the filling die, resulting in misaligned or rejected capsules.
Solutions
✅ Adjust the guide rail width
Verify that the capsule guide rail width is 0.5–1 mm wider than the capsule shell.
Too tight → Capsules become jammed or damaged during transport.
Too loose → Capsules shift left/right, causing misalignment in the die.
✅ Ensure accurate capsule orientation
Check the capsule sorting mechanism and vibratory feeder to ensure consistent orientation of cap and body.
✅ Check the clamping and indexing system
Confirm the filling platform cylinder clamps the capsules firmly at the end of the indexing stroke to prevent movement during dosing.

Problem 2: Filling Hopper Temperature & Humidity Too High
Symptoms
Powder clumping and inconsistent flow in the hopper cause the NJP800C’s dosing system to feed unevenly, leading to capsule weight swings and unstable running paths.
Solutions
✅ Lower the ambient temperature/humidity
Excessive heat or moisture causes hygroscopic powders to clump, disrupting uniform feeding. Maintain hopper conditions within the powder’s recommended RH range.
✅ Check hopper and agitator alignment
Confirm the agitator and dosing disk are parallel to avoid uneven powder distribution that causes bridging and inconsistent filling.

2. Incomplete Capsule Filling: Causes & Solutions

Problem 1: Edge Dosing Wells Not Fully Filled
Symptoms
Capsules positioned at the outer edges of the filling die have significantly under-dosed weights, while central wells appear normal.
Solutions
✅ Check the powder leveling mechanism
If the scraper or leveling plate does not seat tightly against the dosing disk, powder will not fill the edge wells sufficiently.
✅ Inspect for powder bridging and flow issues
Poor powder flow or air entrapment in the hopper can starve the outer dosing positions. Improve powder flow with granulation or adjust the agitator speed to prevent uneven distribution.

Problem 2: Middle Dosing Wells Not Fully Filled
Symptoms
Capsules in the center of the die are poorly filled, with inconsistent or low weights, even as edge wells perform normally.
Solutions
✅ Adjust the hopper height and agitator position
Set the hopper outlet 2–3 mm above the dosing disk, and the agitator blade 3–4 mm above the disk surface.
This prevents powder from compacting in the center and ensures uniform flow to all dosing wells.
✅ Calibrate the tamping pin depth
Adjust the tamping stroke to ensure consistent compression of powder in the middle wells, eliminating loose, under-filled doses.

3. Poor Capsule Sealing & Closing: Causes & Solutions
Problem 1: Capsule Misclosure or Capping Issues
Symptoms
Capsules fail to lock properly, leading to loose caps, split bodies, or high rates of rejected units after the closing station.
Solutions
✅ Check the closing plate alignment
Ensure the upper and lower closing dies are parallel and centered to apply even pressure across all capsules.
✅ Verify capsule size compatibility
Confirm the NJP800C’s tooling matches the exact capsule size and specifications, as mismatched tooling causes misclosure.

Problem 2: Powder Leakage and Cross-Contamination Risks
Symptoms
Excess powder buildup in the closing station causes friction, leading to scratched capsules and contamination between batches.
Solutions
✅ Increase post-filling cleaning frequency
Regularly clean the closing dies and surrounding area to remove powder residue that can interfere with proper closure.
✅ Adjust the vacuum powder removal system
Optimize the vacuum level to remove excess powder from the capsule rims before closing, preventing trapped particles from disrupting the seal.

1.1 Blister Packaging

1.2 Cartoning Packaging