Blister Packing

Blister packing is the process of heat sealing two substrates in order to form a selected number of cavities designed to contain and protect a range of solid dose formats, including Tablets, Pills, Caplets, Two Piece Capsules and Soft Gel Capsules. Wasdell Packaging has many years’ experience in all types of Blister Packing including Cold-Form and is a regular supplier to a number of major Pharmaceutical, Neutraceutical, Vitamin, Veterinary and Healthcare companies.

Blister packed products can be supplied either in bulk or packed with or without PIL’s (Patient Information Leaflets) in cartons, labelled, coded and despatched to meet Customer requirements. Blister Packs can also be presented in a wallet format or card mounted to suit our Customer’s marketing strategy. We also have the expertise and flexibility to be able to supply Multi-Product Blisters where up to four different products can be presented together in one Blister. For variations of design and artwork on Blister Foil, labels and cartons, our artwork team can provide solutions to meet each Customer’s specific requirements.

Thermo Form Blister Packing involves the pre-forming of typically PVC or PVC/PVDC to create a selected number of cavities in strip form which are then filled with product and heat seal laminated to Aluminium foil. The filled and laminated strip is then cropped to a pre-selected size. Wasdell Packaging is also greatly experienced in Thermo Forming blisters in many other alternative materials including COC, Aclar, Polypropylene and Triplex.

Cold-Form Blisters are regarded as providing products with the optimum protection available and there is a growing demand for these types of blisters in the pharmaceutical sector. Our state-of-the-art machinery creates the blister cavities by punch forming Aluminium through pressure rather than heat. The aluminium is then sealed with Aluminium foil. Cold-form blisters can be perforated to allow the separation of individual products from the blister card and can be sealed by peelable foil for each individual cavity.

Tooling. We possess over 600 different sets of blister format tooling in stock for use by our customers free of charge. Having such a wide range of format parts allows us to accommodate most standard products sizes and blister shapes without our customers having to make initial investments in tooling. If new tooling is required however, it can typically be designed and manufactured within two weeks.

Container Filling

Container filling as the name suggests is the process of filling a container with a specific amount or quantity of a product. Wasdell Packaging can fill containers with any desired amount of tablets, capsules, powders, granules, gels, pastes and liquids.

We have the capabilities to fill a wide range of solid products into varying sizes and types of containers. Our filling process is fully automated with counting and filling, label application, cartoning and patient information leaflet inclusion possible on line. We have the capacity to fill over 100,000 containers per day into either glass or plastic and a wide range of closures including tamper evident and child resistant devices are available. To compliment this service the optional addition of cotton wool, foam wads or desiccants can also be completed online.

Liquid Filling - We can also provide the same service of container filling with any amounts of liquid, oil, gel or paste, from 5ml to 5,000ml. We have experience in filling pipettes, bottles and pots and have the capacity to accommodate any volume that may be required. Our latest liquid filling equipment also assists in keeping wastage to an absolute minimum.

Powder Filling -Powders can also be filled into an extensive variety of containers from 5g to 5,000g per unit. Again huge volumes are possible in a very short space of time owing to our latest machinery. These methods are ideal for the packing of protein powders and food supplements/additives for example.

Sachets and Strip Packs

Sachets can be filled with a variety of different products from powders to solids into a variety of materials. We can also place several different solid products i.e tablets/capsules into one sachet, ideal for convenient one a day consumer packs or free samples.

Strip Packs were one of Wasdell Packaging first services and we still provide this service today. With over 35 years of experience in the form of packaging we can produce significant quantities in a variety of different material.

2D Matrixes and Carton Serialisation

In order to adhere to new requirements and legislation for licensed drugs we can now offer 2D data matrixes and carton serialisation to our customers. To minimise the counterfeiting of products in the market place a new format of bar-coding has been developed that allows more details of the product and further traceability to be stored within it. We have the capabilities to print the data matrixes onto the products printed components in-house and can scan them to ensure complete accuracy before they reach the consumer.

We also have the capability to serialise a products packaging to again aid product traceability and minimise counterfeiting. This means that each carton is uniquely coded during production and allows exact quantities to be produced. If a pack is rejected during production, our sophisticated machinery recognises this and will produce a new carton displaying the numerical code to replace the one that has been rejected. Full production reports can then be given to the customer offering full traceability for every individual carton.

Storage and Distribution

Storage and Distribution is an additional service that many of our competitors are unable to offer their customers. However, here at Wasdell Packaging, we have the ability to store in excess of 7,000 pallets on behalf of our customers. Their products can then be called off and delivered globally by Wasdell Packaging to any given schedule. Our facility is also ideally located with it being just minutes from Junction 16, M4. Our distribution warehouses offer the highest levels of security and are temperature controlled. We can also provide cold-storage with our 2,000sqft refrigeration unit onsite and cold-chain distribution if required.

Secondary Packing

These are just some of the Secondary Packaging activities regularly undertaken at Wasdell Packaging:

• Complete Re-packing of product to suite other markets or countries
• Inserting Patient Information Leaflets to suite other languages
• Labelling and Cartoning of primary packed product into
• Display Boxes
• Hand Assembly
• Labelling
• Coding
• Shrink Wrapping
• Cartoning
• Ampoule Vial Labelling
• Inhaler Kit Packing

At Wasdell Packaging we work very closely with many companies based in the retail sector. The majority of the secondary packaging work we undertake involves the packing or repacking of products into different bulk quantities and/or into specific display/presentation units. These include:

• Shelf Ready Packaging
• Hanging Clip Strip Presentations
• Drop Feed Units
• On Line Trays
• Pocket Pack Filling
• Card Wallets