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Part II - Production Variables

Controlling the process to yield optimal results.
Film Heating Station

General Suggestions:

• Use the lowest setting possible to minimize film shrinkage and curl, while still forming complete cavities.
• Make sure platens are flat, parallel in alignment and gap.
• Adjust temperature in 5° increments.
• Heating plate length: 3 indexes.

PVC - Upper and lower platens set to the same temperature, zones need not be increased for best thermoforming results.

or PVdC coating - Platen facing PCTFE or PVdC coating should be lower than that facing PVC. Incremental rise in temperature zones is generally desirable.

Typical Temperature Setting:

T1: 130° C

T2: 135° C

T3: 140° C

T4: 125° C

T5: 130° C

T6: 135° C


Blister Cavity Formation

General Suggestions:

• Always activate plug assist to at least 50% when available (up to 75%). Plug assist aids in more uniform cavity thickness distribution, and usually results in lower platen heat settings.
• Air forming pressure of 60-120 PSI (4-8 bar) is optimal.
• Use matched tooling.

PVC - Almost any cooling conditions and coatings will form cavities.

PVdC coatings - Require Teflon coated cavities to lengthen tool life. Cold tools are discouraged to reduce PVdC cracking.

- These materials may bond with Teflon coatings. Mold temperatures should be “room temperature”. Plug assist is recommended.
Blister Cavity Filling

General Suggestions:

• Always insure improperly oriented solid dosage forms and crushed product are removed prior to the lidstock lamination.
• A change in film gauge will affect product fit into the blister cavity.
• Incompletely formed cavities will negatively affect filling performance.

 
TEKNIFLEX® Laminations - Winding

Lidstock Sealing

General Suggestions:

• Lidstocks generally seal very well to PVC, adequately to PVdC, and poorly to PCTFE layers. Novel lidstocks seal to PCTFE.

• Sealing Temperatures between 170-220O C are used for most PVC coated lidstocks. Universal and Polyolefin lidstocks can be run at 140-200O C.

Note: Curling may occur with PCTFE films at higher sealing temperatures.
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