Blister packaging for nutraceuticals: pack it the safe way

The evolution of nutraceuticals: from food supplement to wellbeing

In recent years, the nutraceutical market has evolved significantly. Once considered an extension of the food sector, it is now increasingly aligned with the pharmaceutical world.

Consumer perception has shifted: nutraceuticals are no longer seen as simple dietary additions, but as essential elements of daily wellbeing, closely associated with health rather than just nutrition.

This transformation has raised production expectations. Hygiene, quality standards, and process control are now aligned with pharmaceutical requirements. A deep understanding of the food sector is no longer enough — solid expertise in pharma regulations and procedures is essential.

To meet these standards, as outlined in GMP guidelines, packaging plays a key role. Among the available options, blister packaging stands out as one of the most suitable solutions to ensure the required levels of quality and safety.

Beyond the pharmaceutical dimension, nutraceuticals retain a strong marketing and image component. Packaging must communicate quality, wellbeing, and reliability, while also attracting the end consumer visually.

In this context, well-established blister formats are being increasingly optimized to:

• Preserve production efficiency
• Ensure operational continuity
• Enable quick format changes

At the same time, blister design is gaining attention. Layout, shape, cavity distribution, and orientation are carefully studied to maximize both aesthetic appeal and functional performance.

This calls for a partner with strong technological expertise and a deep understanding of the specific needs of both the pharma and nutraceutical sectors — one capable of guiding the design toward solutions that combine industrial performance with perceived value.

The result is packaging that not only protects the product but also enhances brand positioning, striking the right balance between functionality and consumer perception.

The blister: protection, value, precision

In this evolving landscape, blister packaging proves to be a particularly effective solution.

It enhances the value of each individual unit, offering a higher perception of quality, while allowing small quantities of tablets or capsules to be packaged with a premium positioning, thanks to the perceived value associated with this format.

Blister packs provide excellent barriers against oxygen, humidity, and light — essential for maintaining product efficacy and extending shelf life. This is especially important in the nutraceutical field, where active ingredients such as vitamins and probiotics are often sensitive and require protection.

Blisters are irreplaceable for fragile, hygroscopic, or photosensitive products.

The single-cavity configuration also supports proper intake timing, making blisters ideal for:

• Cyclic treatments
• Temporary supplement regimens

Consumers appreciate blister packaging for its:

• Accurate dosing
• Convenient single-dose format
• Ease of transport

The ability to separate doses also reduces contamination risk, increasing safety and hygiene.

The advantages of blister packaging

A market in search of more sustainable and high-performance materials

The nutraceutical sector is increasingly focused on sustainability and packaging circularity, driven by growing consumer awareness.

This shift is leading to the adoption of:

• PVC-free materials
• Recyclable and eco-friendlypackaging solutions

At the same time, regulatory frameworks may evolve toward stricter sustainability criteria. In this context, investing in machines and packaging lines capable of handling innovative materials becomes a strategic choice.

Technologies must:

• Deliver high performancewith new polymers
• Ensure a smooth transitionto sustainable solutions
• Maintain production efficiency

Examples of sustainable blister materials:

• Mono PP
• Mono PET
• Mono PE

Mono PP blister	Mono PET blister	Mono PE

Precise handling and feeding systems tailored to each product

Blister packaging involves sensitive production phases, especially during product feeding, when tablets or softgels are still exposed and vulnerable.

This stage requires dedicated systems capable of handling:

• Friable
• Dusty
• Irregularly shaped
• Softgel products
• Sticky products

Despite high automation, each solution must be customized based on the product’s characteristics.

IMA Safe feeders are designed to:

• Match the shape, consistency, and sensitivity of the product
• Ensure 99.90% efficiency
• Preserve product integrity

Given the variability of nutraceutical batches, IMA Safe develops dedicated feeding systems that combine:

• Industrial reliability
• Delicate handling
• Tailor-made solutionsfor a constantly evolving market

Compact and flexible cartoning: tailored lines for Nutraceuticals

The nutraceutical market is characterized by:

• Small production batches
• High product variety

This requires compact, flexible, and easy-to-manage secondary packaging solutions.

Key features include:

• Rapid format changeoverswith minimal component replacement
• Handling of bulky formatsor multiple blisters per carton
• Consistent precisionin insertion and closure

IMA’s compact cartoning machines for low and medium speeds:

• Reduce footprint
• Simplify integration in limited spaces

An added advantage is the ability to rely on a single partner for both primary and secondary packaging. This ensures:

• Design consistency
• Perfect machine interoperability
• Unified operating interface

This integrated approach is ideal for manufacturers with broad and dynamic product portfolios, enabling:

• Modular, scalable solutions
• Quick adaptationto new launches and formats

In this context, quick and easy format changeovers are increasingly in demand — even at moderate speeds.
The ability to handle different configurations on the same machine, with minimal adjustments, is key to improving operational efficiency.

Integrated solutions: winning combinations for Nutraceuticals

Depending on production needs, optimal lines can be configured by combining blister and cartoning solutions:

• TR135–A83: for low and medium-speed production, offering high reliability and compactness
• C40–A46: ideal for small to medium batches and frequent format changes, with automatic format change functions

TR135-A83: low and medium-speed production, high reliability, and maximum compactness	C40-A46: compact line ideal for small to medium batches and frequent format changes, thanks to automatic format change functions

Conclusions: the importance of quality in nutraceutical packaging

As the nutraceutical market continues to evolve, ensuring safe, effective, and high-quality products becomes increasingly critical.

Blister packaging remains the ideal solution to meet these demands, offering:

• Protection of active ingredients
• Long shelf life
• Compliance with the highest safety standards

With specialized lines and deep expertise in product handling, blister packaging is a reliable partner for the nutraceutical industry – supporting the growing need for flexible, high-performance solutions that protect product integrity right up to the moment of use.