Forming and sealing path
Review the tooling station, web alignment and inspection access for the selected package format.
Blister Packing
Automatic Blister Packing Machine
Form pockets, feed the product and seal the lidding material into finished blister cards. Select the forming method, feeder and tooling for your tablet or capsule format.
- 3 DPP modelscompare forming formats
- ALU-PVC / ALU-ALUselect forming configuration
- Product toolingpocket and card layout
A CLOSER LOOK
Follow the web
through the machine.
Review the equipment photographs alongside the application, access and changeover requirements for your process.
Web transfer and tooling
Review the web path, change parts and access along the packaging stations.
Station layout and access
Review how the selected stations are arranged for your forming web and lidding material.
Catalogue equipment photographs; the selected model, tooling and appearance are confirmed with your quotation.
WORKING PRINCIPLE
See the complete blister process
Explore the six-stage animation on our category page, including ALU/PVC pressure forming and ALU/ALU mechanical cold forming.
CHOOSE YOUR BLISTER FORMAT
ALU/PVC or ALU/ALU?
Start with your product.
Balance protection, pack size and production requirements. The forming web, lidding foil and tooling work together; material choice belongs in the machine-selection discussion.
Thermoformed blister
ALU/PVC
A PVC forming web makes the pockets; aluminum foil closes them. Clear PVC offers product visibility and flexible cavity layouts.[2]
- Useful when visibility, compact formats and productive line operation matter.
- Evaluate plain PVC against the protection your formulation needs.
Transparent blister reference; the photographer does not identify the polymer grade. Photo: Michiel4 · CC BY-SA 4.0 · unmodified.
Cold-formed blister
ALU/ALU
An aluminum-containing laminate makes the pockets; aluminum foil closes them. The intact aluminum layer provides very high protection against moisture, oxygen and light.[1]
- Useful when the product needs a high protective barrier.
- Balance that protection against the selected format and operating rate.
Cold-form blister reference. Photo: Michiel4 · CC BY-SA 4.0 · unmodified.
Reference photographs illustrate pack appearance. They are not Encap production samples or evidence of a specific material specification.
What is inside the package?
Open ALU/PVC drawing
Open ALU/ALU drawing
Encap explanatory illustrations · not to scale. Adhesives and surface coatings are simplified. Final materials, gauges and cavity geometry are selected for the package.
Compare the practical trade-offs.
Scroll across to compare formats →
| Consideration | ALU/PVC · plain PVC | ALU/ALU · cold form |
|---|---|---|
| Forming method | Heat softens the plastic web before vacuum / pressure forming. | A mechanical tool draws the laminate into cavities without heating the forming web.[5] |
| Moisture & oxygen | Plain PVC has a comparatively limited barrier. Enhanced polymer structures are a separate choice. | The intact foil layer offers a very high barrier. Forming defects and seal integrity still matter.[1][4] |
| Light & visibility | A clear web lets the customer see the product; it does not provide the opacity of foil. | Opaque aluminum shields the product from light and hides it from direct view.[1] |
| Cavity layout & pack size | Can support compact layouts and close cavity spacing. | Conventional cold-form geometry can require more area. Draw depth, radii and laminate grade determine the final footprint.[4] |
| Production rate | Often permits a higher cycle rate on a comparable machine and format. | Often runs at a lower cycle rate. Check the actual model, cavities per cycle and demonstrated settings.[6] |
| Cost considerations | Plain PVC is generally an economical starting point. Include material usage, tooling and output in the comparison. | Often involves higher material / tooling cost. Pack area, setup waste and accepted output determine total cost per pack.[4] |
| Selection starting point | Consider it when a clear, compact pack meets your product’s protection requirements. | Consider it when product sensitivity calls for stronger moisture, oxygen or light protection.[1][3] |
Need a clear pack with more barrier?
PVDC-coated PVC and PCTFE laminates offer enhanced-barrier thermoforming options. Their performance differs from plain PVC; review the exact film grade, tooling and sealing compatibility.[3]
Cold forming still needs a sealing step.
“Cold form” describes how the cavity is made. The selected lidding foil is still heat-sealed to the compatible inner layer of the forming web.[2]
ON THE EQUIPMENT YOU ARE SELECTING
DPP-260 catalogue example
ALU/PVC6–70cutting cycles/min
ALU/ALU6–50cutting cycles/min
These are catalogue ranges for the DPP-260, not a universal speed ratio. Blisters per minute also depend on blisters per cutting cycle, the product, feed system and selected format.
Compare the DPP model specifications ↓Match the package to your product.
Bring your product dimensions, protection requirements, film specification and target output. We can review the forming configuration, tooling and trial goals together. Shelf-life suitability needs product-specific stability evidence.
Technical references & image credits
- Amcor — Formpack® Blister System: aluminum-laminate barrier and cold-form configurations.
- Bilcare — Pharma Packaging Innovations: PVC, enhanced polymer structures, OPA / foil / PVC and heat-seal lidding constructions.
- Klöckner Pentaplast — Pharma & Nutraceutical and Pentapharm® portfolio: plain PVC through enhanced-barrier thermoforming films.
- Honeywell — Strategic Implications of Generic Sector Packaging: format footprint, output and total-cost considerations. Supplier-authored comparison; no percentage saving is applied to this equipment.
- Constantia Flexibles — Forming Simulation: mechanical drawing and cavity design.
- Encap DPP-140 / 250 / 260 catalogue model references: machine-specific cutting frequencies.
Reviewed October 19, 2026. Summary and drawings by Encap; generalized material differences are not package test results. No universal WVTR, OTR or shelf-life value is assigned.
Photographs by Michiel4, via Wikimedia Commons: Pharmaceutical Blister Pack and Cold Form Foil blister pack2. Both are used unmodified under CC BY-SA 4.0. Their authors do not endorse Encap.
Plan the machine around your blister card.
Review forming materials, product feeding, tooling, accepted output and the evidence to collect in a trial.
CONFIGURATION & SELECTION
DPP-140 / DPP-250 / DPP-260 / CONFIGURATION REFERENCEKnow what you
are selecting.
Catalogue selection reference. Output depends on the product, tooling and operating conditions. Final specifications, utility loads and supplied options are confirmed for the machine in your quotation.
Bring these details to the discussion
- Tablet / capsule samples and pocket layout
- ALU-PVC or cold-form ALU-ALU format and lidding film
- Card size, output target and downstream cartoning
| Model range | DPP-140 / DPP-250 / DPP-260 |
|---|---|
| Speed interpretation | Cutting cycles/min; cards and pockets per cycle depend on tooling |
| US three-phase configuration | 220V, 3-phase, 60Hz; connected loads confirmed in quotation |
Need the configuration sheet or layout?Ask our team for the model-specific specifications, utility requirements and equipment scope for your project. Technical details are confirmed in your quotation.
COMPARE CONFIGURATIONS
Choose the size
for your process.
Compare catalogue model references. Confirm the selected model and demonstrated results for your product before ordering.
Scroll across to compare models →
| Model | DPP-140 | DPP-250 | DPP-260 |
|---|---|---|---|
| Cutting Frequency (times/min) | ALU-PVC: 10-50 ALU-ALU: 10-25 | ALU-PVC: 6-50 ALU-ALU: 6-25 | ALU-PVC: 6-70 ALU-ALU: 6-50 |
| Adjustable Travel Range (mm) (Can be customized) | 40-140 | 40-160 | 0-220 |
| Max. Forming Area (mm) | 140×130 | 240×150 | 240×150 |
| Max. Forming Depth (mm) | 26 | 26 | 26 |
| Air Pressure (MPa) | 0.4-0.6 | 0.4-0.6 | 0.4-0.6 |
Catalogue references · Capacity, output and operating settings depend on the selected format and product. Final parameters are confirmed in your quotation.
SUPPORT THROUGH PRODUCTION
The equipment is
only the beginning.
Practical support from selection through production. Services, scheduling and responsibilities are agreed for your project.
Select & plan
Review the application, equipment scope, FAT and delivery plan before the machine ships.
Discuss your projectInstall & start up
Arrange installation assistance, commissioning, operator training and production coaching.
Explore startup supportKeep production moving
Talk with our San Diego team about maintenance, troubleshooting, parts and repair.
Ask for technical supportPLAN THE NEXT STEP
Build the process
around your product.
Explore related equipment, then review which items belong in your project scope with our team.
EQUIPMENT FINANCING
Plan the machine.
Explore the payment options.
Ask about financing for an eligible equipment purchase, with an equipment quote and payment terms reviewed together.
Financing is subject to approval and program availability.
Catalogue specification
Confirm the exact model, current configuration, utilities and included equipment with our team before ordering.
Download catalogue spec sheet (PDF) · 4.0 MB