Form, Fill, & Seal Packaging
What is Form, Fill and Seal Packaging?
Form, Fill & Seal packaging aka FFS blister packs is exactly that. Forming the blisters, filling the blisters and sealing the blisters. All inline, on one machine. The process is as follows: The packaging materials (usually pharma grade PVC for the blisters & pharma grade foil for the backing) are fed into the back of the machine. The plastic is then molded using an aluminum form tool. This tooling forms a custom blister tailored to the product’s shape and size. The machine then fills the formed blister with the product at a sterile, contamination-free filling station. As the blister advances to the cutting station, a foil backer is sealed to the blister. All of this is done inline on one machine in one of Premier Plastic, LLC’s class 8 cleanrooms.
​
Once the now sealed blister is cut out from the web, the finished blister can either be bulk packed or sent to our automated carton filler. The carton equipment not only erects the single use carton, but fills it with the desired number of blister packs. At this point the carton is then sealed on both ends with pharma glue, providing a tamper evident package. All of this can be done at speeds of up to 1 unit every 2 seconds.
​
Premier Plastics, LLC does have some stock tooling/ blister sizes as well as tooling for the machine's high speed carton loader. Additionally, Premier Plastics, LLC can build custom tooling should the need exist. For more information on Premier’s stock or custom FFS blister options, please call us at 801-975-0133 or send an email to: customerservice@premierplastics.net
What are the advantages of Form, Fill, & Seal Packaging?
Efficiency and Speed: By completing the entire process—forming, filling, and sealing—on a single machine, FFS packaging minimizes handling and shortens production times. This high-speed automation enables higher output and faster turnaround.
Cost-Effectiveness: Integrating all steps into one machine reduces the need for separate machinery and labor, lowering overall operational costs. Additionally, it minimizes material waste due to precise portioning and reduces packaging expenses by creating custom packaging in-line.
​
Product Freshness and Safety: FFS machines often include contamination-free filling stations, ensuring the product is protected from external contaminants. This makes FFS ideal for consumable products such as vitamins, nutraceuticals, CBD and Kratom.
Versatile Design Options: These machines allow for customizable cavity molds and flexible packaging formats, enabling companies to create unique, brand-specific packaging shapes and sizes that enhance product presentation.
Is FFS packaging right for my product?
Whether Form, Fill & Seal (FFS) blister packaging is right for your product depends on several factors. These are related to your product type, production needs, and packaging goals. Here are a few considerations to help determine if FFS packaging is suitable for you:
​
Product Type: FFS packaging works well for products that need protection from contamination, such as vitamins, nutraceuticals, CBD & Kratom. It’s also ideal for products that require portioning or single-serve packaging. If your product is sensitive to environmental factors like moisture or oxygen, FFS packaging can provide an effective barrier against those elements.
​
Production Volume: FFS is efficient for high-volume production since it automates forming, filling, and sealing in one step. If your production needs are high, FFS can save time, reduce labor costs, and increase throughput.
​​
Product Shelf Life: For perishable or sensitive products, FFS can enhance shelf life with secure, non-contaminated filling and sealing. This is particularly useful for products such as vitamins, nutraceuticals, CBD & Kratom.
What type(s) of products can Premier Plastics, LLC package or handle on our FFS equipment?
Premier Plastics, LLC is licensed by the state of Utah to handle and package the following type(s) of products:
-
Vitamins
-
Nutraceuticals
-
CBD & Kratom
We are NOT licensed to package or handle any pharmaceutical, OTC’s or cannabis products.