How To Change Blister Packing Machine Mold

Views: 17 Author: Hunan Grand packing machine Publish Time: 2026-01-29 Origin: Hunan Grand Packing Machinery

DPP-80 Blister Packaging Machine Mould Change Procedure & Operational Guide

A complete video demonstrating the mold replacement procedure can be found at the end of the article. It is recommended to read the written instructions first before watching the video.

Essential Safety Notices:

Lockout/Tagout: Before commencing ANY disassembly or assembly work, you MUST completely isolate the machine from all power sources (electrical, pneumatic). Engage lockout devices and attach a clear warning sign: "UNDER MAINTENANCE - DO NOT OPERATE".
Qualified Personnel: This procedure must only be performed by trained technicians familiar with the machine's mechanical structure.
Tool Preparation: Prepare appropriate lifting equipment (hoist, crane), Allen keys, copper or soft-faced hammers, cleaning tools, lint-free cloths, and lubricants.
Mould Protection: Moulds (especially cavities and sealing surfaces) are precision components. Handle with extreme care during lifting, transport, and storage to avoid damage.

Overall Mould Change Process

Preparation → Removal of Old Moulds → Installation of New Moulds → Calibration & Test Run

1. Preparation

Confirm Moulds: Verify the correct Upper Forming Mould (Punch), Lower Forming Mould (Die), Heat Sealing Mould, and corresponding Cutting Die against the production order. Inspect for any damage.
Clean Area: Thoroughly clean the work areas of the forming, sealing, and cutting stations. Remove all old PVC/Aluminium foil debris and grease.
Position Machine: Manually crank the machine (if possible) or jog it to a safe, open position providing full access to all moulds.
Prepare Tools & Lifting Gear: Position the lifting equipment (overhead crane or chain hoist) directly above the mould stations. Ensure lifting slings/straps are in good condition.

2. Removal of Old Moulds

A. Upper Forming Mould (Punch)

Isolate & Disconnect Services: Lockout pneumatic supply. Disconnect and cap coolant hoses and vacuum lines connected to the upper mould.
Secure for Lifting: Attach lifting slings securely to the upper mould.
Remove Fixing Bolts: Using the correct size Allen key, loosen and remove all bolts securing the mould to the upper platen in a diagonal sequence.
Detach & Remove: Apply slight tension with the hoist. Gently tap the mould sideways with a soft mallet to break any seal. Once free, lift the mould clear and place it on a dedicated mould stand or protective surface.

B. Lower Forming Mould (Die)

Clean: Remove any debris from the lower mould cavity.
Remove Fixing Bolts: Remove all bolts securing the lower mould to the lower platen.
Lift Away: Carefully lift and remove the lower mould.

C. Heat Sealing Mould

Isolate: Ensure the sealing station heater power is off and the unit has cooled to a safe temperature. Isolate pneumatic supply to cylinders.
Remove Upper Seal Plate: Unbolt and remove the upper sealing plate. Note the internal heating elements and thermocouples.
Remove Lower Seal Plate: Unbolt and remove the lower sealing (embossing) plate.

D. Cutting Die

Position: Manually crank the cutting station to its fully open position.
Remove Upper Cutting Die (Punch): Loosen the bolts or clamps securing the upper die and remove the assembly.
Remove Lower Cutting Die (Anvil/Die Plate): Unbolt and remove the lower die plate. Protect the sharp cutting edges.

3. Installation of New Moulds

A. Lower Forming Mould (Die)

Clean & Inspect: Clean the lower platen mating surface thoroughly.
Positioning: Hoist the new lower mould into position, aligning it roughly with locating pins or datum edges.
Initial Fixing: Hand-tighten all fixing bolts.
Final Alignment & Tightening:

Insert locating pins (if applicable).
In a diagonal sequence, tighten all bolts evenly in two stages (first snug, then final torque). This ensures even clamping without distortion.
Use a torque wrench to achieve the specified torque (refer to machine manual).

B. Upper Forming Mould (Punch) – Critical Alignment Step

Clean: Clean the upper platen mating surface.
Alignment & Lowering: Hoist the upper mould into position. Very slowly lower it, using the guide pillars, to achieve a rough alignment with the lower cavity.
Manual Crank Trial Closure (Key Step): Use the manual crank to drive the upper platen down extremely slowly for a trial closure. Constantly observe. Stop immediately if any binding or misalignment is detected and correct.
Final Closure & Fixing: Once the moulds close fully and correctly, raise the upper platen slightly (1-2mm). The mould should be flush with the platen without pressure.
Tighten Bolts: Tighten all upper mould bolts in a diagonal sequence.
Reconnect Services: Reconnect coolant and vacuum lines. Check for leaks.

C. Heat Sealing Mould

Install Lower Seal Plate: Install and secure the lower sealing/embossing plate. Ensure alignment with the forming area.
Install Upper Seal Plate: Install the upper plate, reconnecting heating elements and thermocouples securely and correctly.
Adjust Parallelism & Pressure: After installation, check the parallelism of the sealing faces using a feeler gauge or shim stock. Adjust using the machine's built-in mechanisms. Set a preliminary sealing pressure.

D. Cutting Die

Install Lower Die: Install and secure the lower anvil/die plate.
Install Upper Die: Install and secure the upper punch assembly to the ram.
Adjust Cutting Depth & Alignment (Key Calibration): This is crucial. Use the machine's adjustment screws to finely set the punch depth to ensure clean cuts without excessive wear. Simultaneously, align the cutting position precisely with the blister strip.

4. Calibration & Test Run

Manual Crank Check: With power OFF and heaters OFF, manually crank the machine through at least 2-3 full cycles.

Verify smooth operation at all stations with no binding or unusual noise.
Check alignment between forming, sealing, and cutting stations.

Power On Dry Run: Reconnect power (heaters OFF). Run the machine in slow jog or intermittent mode without material. Observe all mechanical motions.
Parameter Setup: On the HMI, enter the production parameters for the new mould set:

Forming Station: Heater plate temperature, forming air pressure, cooling time, vacuum level.
Sealing Station: Sealing temperature, dwell time (or speed), sealing pressure.
Cutting Station: Cutting stroke timing (synchronisation with indexing).

Heating & Material-Less Test:

Switch on heaters. Allow temperatures to stabilise at setpoints.
Thread PVC and Aluminium foil (or laminate). Run a material-less test to check forming shape, seal pattern, and scrap removal.
Perform preliminary longitudinal and lateral print/emboss registration.

Test Production with Product:

Observe blister formation (fully formed, no thinning, no webbing).
Check seal integrity (uniform, strong, no channels).
Check cut quality (clean edges, no burrs, no connected blisters).
Make minor adjustments to temperature, pressure, timing, and registration as needed.

Load product (tablets, capsules). Initiate a low-speed test run.
Fine-Tune Adjustments:

High-Speed Validation & Documentation: Gradually increase speed to the target production rate. Confirm stable operation and consistent quality. Lock parameters. Record the final, validated production parameters in the mould log or production documentation.

Key Points to Note

Alignment is Paramount: The precise alignment within each station (upper/lower) and between the forming, sealing, and cutting stations is critical for success. Patience is essential.
Temperature Management: Allow new moulds to heat up gradually during the first heating cycle to minimise thermal stress. Ensure adequate pre-heating time before production.
Safety First: During calibration, never place any part of your body into the closing zones. Use tools for observation and adjustment.
Consult Official Documentation: This guide provides a general procedure. Always prioritise the instructions in the official 'DPP-80 User Manual', specifically the chapter on mould changing, and adhere to all safety labels on the machine itself.