Primary Packaging
High-speed blister, bottle, vial, syringe, and sachet packaging across all major dosage forms - delivered with integrated vision inspection and 100% in-process verification.
OVERVIEW
Primary packaging is where product meets patient. At Meridan, our primary packaging operations encompass the full range of dosage forms and material configurations required by today's pharmaceutical and biotechnology companies. From high-volume blister lines running at speeds exceeding 400 blisters per minute to precision vial labeling for injectable biologics, every line is designed for speed, accuracy, and regulatory compliance.
Our primary packaging capabilities span three FDA-registered facilities, providing both geographic redundancy and the capacity to support large-scale commercial programs alongside smaller specialty runs. Each line is equipped with integrated camera inspection, in-line check weighing, and real-time data collection that feeds directly into our batch record and serialization systems. This level of integration ensures product quality at every stage while enabling rapid changeover between products and configurations.
BLISTER LINES
Blister Packaging
Our blister packaging lines support the full spectrum of thermoform and cold-form materials, including PVC, PVDC, Aclar, and cold-form aluminum. This material flexibility allows us to match barrier properties precisely to the stability requirements of each product, whether it demands basic moisture protection or the highest level of oxygen and light barrier performance that cold-form aluminum provides.
Lines run at speeds up to 400 blisters per minute with continuous in-line vision inspection that verifies fill accuracy, tablet orientation, seal integrity, and print registration on every blister. Missing dose detection, foreign particle inspection, and lid foil verification are standard across all configurations. Our blister operations support both standard cavity formats and custom tooling for specialized dosage forms including combination packs, calendar packs, and wallet configurations.
- ✓Thermoform and cold-form blister configurations
- ✓PVC, PVDC, Aclar, and cold-form aluminum materials
- ✓Speeds up to 400 blisters per minute
- ✓100% vision inspection with missing dose detection
- ✓Calendar packs, wallet packs, and combination blister formats
BOTTLE LINES
Bottle Packaging
Our bottle packaging lines handle both HDPE and card-dark bottles across a range of sizes from 15cc through 1000cc, supporting tablets, capsules, soft gels, and powder fills. High-accuracy electronic tablet and capsule counting systems ensure precise fill counts, while integrated cotton insertion, desiccant insertion, and induction sealing deliver complete package closure and moisture protection.
Every bottle line features in-line check weighing to verify fill counts, torque testing for cap closure verification, and induction seal inspection to confirm hermetic seals. Our bottle operations also support child-resistant closures, tamper-evident banding, and a range of closure types including continuous thread, snap caps, and dropper assemblies for ophthalmic and otic products.
- ✓HDPE and card-dark bottle configurations (15cc to 1000cc)
- ✓Electronic counting with in-line check weighing
- ✓Cotton and desiccant insertion
- ✓Induction sealing and closure torque verification
- ✓Child-resistant and tamper-evident closure options
INJECTABLES
Vial & Syringe Packaging
Meridan provides comprehensive packaging services for pre-filled vials and syringes, supporting the growing biologics and injectable market. Our vial packaging capabilities include vial labeling with wrap-around and flag label application, vial tray loading, and secondary cartoning of labeled vials. For pre-filled syringes, we offer syringe assembly including backstop and plunger rod insertion, needle shield application, and syringe labeling with full serialization.
These operations are conducted within controlled environments that maintain appropriate temperature and particulate conditions for injectable products. All vial and syringe packaging lines include 100% camera-based label inspection to verify label placement accuracy, barcode readability, and content correctness. Our processes are designed to integrate with upstream fill-finish operations, accepting product in tubs, trays, or bulk configurations.
- ✓Vial labeling with wrap-around and flag label formats
- ✓Pre-filled syringe assembly and labeling
- ✓Controlled environment operations for injectables
- ✓100% camera inspection for label accuracy and barcode readability
- ✓Integration with fill-finish supply chains
POUCHES & SACHETS
Pouch & Sachet Packaging
Our pouch and sachet packaging capabilities support single-dose and multi-dose configurations for powder, granule, and liquid formulations. Stick pack formats are available for oral powder products, providing patient-friendly dosing that supports compliance and convenience. Flat sachets accommodate a range of fill weights and product types including topical creams, oral solutions, and dry powder formulations.
Sachet and pouch lines feature gravimetric and volumetric filling systems with in-line check weighing to ensure fill accuracy across every unit. Seal integrity testing, burst testing, and leak detection are integrated into the production process to verify package closure. Our pouch lines support a variety of film structures including foil laminates, metalized films, and clear barrier films selected to meet the specific moisture, oxygen, and light barrier requirements of each product.
- ✓Single-dose sachets and stick packs
- ✓Powder, granule, and liquid fill capabilities
- ✓Gravimetric and volumetric filling systems
- ✓Integrated seal integrity and leak detection
- ✓Foil laminate, metalized, and clear barrier film options
TECHNOLOGY
Equipment & Technology
Our primary packaging operations are built on proven, high-performance equipment from the industry's leading manufacturers. Every machine is fully validated and maintained within a comprehensive preventive maintenance program. This equipment base gives us the flexibility to handle a wide range of product types and package configurations while maintaining the speed and reliability that large-scale commercial programs require.
Primary Equipment Fleet
Blister Lines
- Uhlmann B1240
Thermoform blister line, up to 400 blisters/min - Uhlmann BLB 600
Compact blister line, up to 230 blisters/min - IMA C2155
High-speed thermoform blister, up to 350 blisters/min
Bottle & Specialty Lines
- Marchesini MB430
Bottle line with counting, capping, and labeling, up to 200 bottles/min - Kalish MonoCount
Electronic tablet/capsule counter with check weigher - NJM / CL Series
Integrated bottle labeling with vision verification
Related Certifications
- •FDA-registered facilities (21 CFR Parts 210/211)
- •Health Canada Drug Establishment License
- •cGMP compliant operations
- •DEA licensed (Schedule II-V)
- •ISO 13485:2016 (medical device packaging)
- •Serialization-ready across all primary lines
Related Resources
View Case Study: High-Speed Blister Line MigrationReady to optimize your packaging operations?
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