Sustainable blister packaging improves machine efficiency

IWK Verpackungstechnik GmbH develops packaging systems for industries including pharmaceuticals, medical technology, cosmetics, and consumer goods. Increasing regulatory pressure and sustainability targets have driven demand for packaging solutions that reduce environmental impact while maintaining high productivity.

A key challenge was to eliminate plastic from blister packaging while preserving structural integrity and throughput. At the same time, manufacturers required improvements in energy efficiency, machine speed, and operator ergonomics, alongside reduced downtime and maintenance needs.

To address these requirements, IWK developed the CABLIblue 870 card-to-card blister packaging system, designed to process fully recyclable cardboard materials and support circular economy objectives.

Solution: Electrical Automation for High-Performance Packaging
To enhance machine performance, IWK integrated electrical automation technology from Festo.

The system relies on EMMS-ST stepper motors to enable coordinated and superimposed movements across multiple machine functions. This allows higher operating speeds while maintaining precise control. In addition, the use of electrically driven components contributes to lower overall energy consumption and reduced noise levels.

Vacuum handling is managed through OVEM vacuum generators, which incorporate air-saving functions and condition monitoring capabilities. These features help stabilize operations and minimize unplanned downtime.

The handling system for blister packs uses electric axes (EGC and ELCC) to ensure consistent positioning and transfer. Magazine systems for packaging materials are also motorized, allowing operators to refill materials more easily during operation, improving ergonomics and reducing manual strain.

Deployment: International Engineering and Integration
The development and assembly of the CABLIblue 870 were carried out across multiple locations, including a major contribution from IWK’s production site in Thailand.

Festo supported the deployment through digital engineering tools and local technical collaboration. Engineering teams in different regions were able to use standardized tools and components, ensuring consistency in system design and implementation.

Close coordination between IWK and Festo enabled rapid component availability and streamlined integration, even in cases where parts were not initially stocked locally.

Results: Increased Throughput and Reduced Environmental Impact
The CABLIblue 870 achieves a packaging output of 22 cycles per minute, representing an improvement of approximately 10% over typical industry performance. This increase is supported by synchronized motion control enabled by stepper motor technology.

Energy consumption is reduced through the use of efficient electric drives and optimized vacuum generation, contributing to a lower carbon footprint. Noise levels are also reduced to below 72 dBA, improving working condition.

From a sustainability perspective, the system enables plastic-free blister packaging using recyclable cardboard, aligning with circular economy goals.

Operationally, integrated condition monitoring and improved ergonomics enhance machine availability and ease of use, supporting continuous production in high-volume environments.

Conclusion
By combining recyclable material processing with advanced electrical automation, IWK has developed a packaging solution that addresses both environmental and operational challenges. The collaboration with Festo illustrates how integrated motion control, energy-efficient components, and digital engineering tools can improve the performance and sustainability of modern packaging systems.

Edited by an industrial journalist Sucithra Mani with AI assistance.

www.festo.com