Manufacturing Processes for Pharmaceutical Boxes

Here’s an overview of the **manufacturing processes for pharmaceutical packaging boxes:

---

### 1. **Material Selection**  

   - **Primary Materials**:  

     - **Paperboard/Cardboard**: Common choices include white-coated duplex, folding boxboard (FBB), or solid bleached sulfate (SBS) for rigidity and printability.  

     - **Plastic**: Used for blister packaging (e.g., PVC, PVDC, or eco-friendly alternatives like PET).  

     - **Foil Laminates**: Aluminum foil for moisture and light protection.  

   - **Sustainability**: Increasing use of recyclable or biodegradable materials (e.g., FSC-certified paper, PLA plastics).  

---

### 2. **Printing and Labeling**  

   - **Offset Lithography**: High-quality printing for logos, branding, and regulatory text (e.g., dosage instructions, barcodes).  

   - **Flexography**: Used for large-volume runs and simple designs.  

   - **Digital Printing**: Ideal for small batches or variable data (e.g., serial numbers, QR codes).  

   - **Special Finishes**:  

     - **Embossing/Debossing**: Raised or recessed text for tactile branding.  

     - **Hot Foil Stamping**: Adds metallic accents for premium packaging.  

     - **UV Coating**: Enhances durability and gloss.  

---

### 3. **Die-Cutting and Creasing**  

   - **Die-Cutting**: Custom steel dies cut the paperboard into specific box shapes (e.g., tuck-end, sleeve, or clamshell designs).  

   - **Creasing**: Creates fold lines for precise assembly.  

   - **Automated Systems**: Rotary die-cutters for high-speed production.  

---

### 4. **Blister Packaging (for combo packs)**  

   - **Form-Fill-Seal (FFS) Process**:  

     1. **Thermoforming**: Heated plastic sheets are molded into cavities to hold pills.  

     2. **Product Loading**: Tablets/capsules are placed into cavities.  

     3. **Lidding**: Sealed with foil or paperboard backing using heat or adhesives.  

   - **Child-Resistant Features**: Requires specialized lidding materials or tear-resistant designs.  

---

### 5. **Folding and Gluing**  

   - **Automatic Folder-Gluers**: Machines fold pre-cut paperboard and apply glue to seams.  

   - **Tray Forming**: For rigid boxes, layers of paperboard are pressed and bonded.