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Spanish Rising demand for foil-sealed butter portions drove a well-known U.S.-based food company to upgrade its blister packaging line, dramatically boosting speed and efficiency.
Key Takeaways:
A well-known U.S. food company replaced its semi-automatic blister packaging line, which produced only 10–35 trays per minute, with Yundu’s fully automatic YDSH-120 Blister Packaging Machine. The upgrade increased production to 180 trays per minute while resolving persistent labor shortages, product defects, and cleaning inefficiencies. With improved throughput, precision filling, superior hygiene, and seamless integration, the company now plans to purchase multiple YDSH-120 units to support future expansion.
Demand Surge Creates Production Bottleneck
Faced with a surge in orders for foil-sealed butter trays, the food company discovered its packaging line was hopelessly underpowered. “Our old blister packager was reliable, but it simply couldn’t keep up,” recalls the company’s production manager. The semi-automatic machine could only run 10–35 trays per minute, requiring four operators to feed, seal, and inspect packages by hand. As demand rose, daily production targets were missed, and shipments fell behind schedule. In the words of one engineering lead, “We hit a ceiling – orders kept coming in faster than we could pack them.” Industry observers note that sharp spikes in demand can “triple production output almost overnight” – something an aging manual line cannot match. The company realized it needed a high-speed, fully automatic blister packaging solution to break through the bottleneck.
Yundu’s YDSH-120 Blister Packaging Machine Accelerates Production
The fully automated YDSH-120 forms, fills, and seals foil trays in a continuous high-speed process, vastly outperforming older semi-automatic equipment. To meet the new demand, the company turned to Yundu Machinery’s YDSH-120, a double-sided thermoforming Blister Packaging Machine designed for high-volume food packaging. This integrated system forms plastic tray cups, dispenses butter into each cup with high precision, and heat-seals them under foil—all in one continuous flow. Modern blister machines like the YDSH-120 are “engineered for speed, capable of processing thousands of packages per hour”, and they are built with “precision, reliability, and hygiene” as design pillars. In practice, the YDSH-120 delivered exactly that: output climbed to about 180 butter cups per minute (over 10,000 per hour) – roughly five to eighteen times the old rate. The production manager reports that “upgrading to the YDSH-120 was a game-changer: we went from wrestling with 35 trays per minute to a smooth 180 per minute line almost overnight.”
From Manual Labor to Automated Efficiency
Before the upgrade, the packaging line was labor-intensive. Two operators fed empty cups into the old machine while others handled foil lids and packed completed trays. This hands-on approach was slow and inconsistent. “We had shift after shift with people manually making up the packs,” says a veteran plant operator. The manual process also caused frequent downtime: the equipment had to be stopped two or three times per shift for sanitation. Faulty fills and incomplete seals were common, with up to 10–15% of packs rejected for errors.
Switching to the YDSH-120 immediately relieved these problems. Only one technician is now needed to oversee the automated line, freeing the rest of the team for higher-value tasks. According to industry analyses, automated blister packaging “significantly reduces labor costs” because the machine handles repetitive tasks. In this case the company reassigned three former pack-line operators to quality control and maintenance, using their skills more strategically. The production manager estimates this reallocation saves over $100,000 per year in labor. At the same time, the servo-driven fill pumps and precise motion control eliminated nearly all of the previous defects. “We used to scrap cases of packages; now rejects are almost zero,” says a quality supervisor. Automated blister packaging machines also “deliver consistent and uniform packaging, minimizing the risk of human error”, and that was evident in the new line’s performance.
Precision Filling and Quality Control
The YDSH-120’s advanced controls ensure each butter tray is filled to exactly the right level. A product engineer explains: “We have a servomotor-driven pump system that meters the butter very precisely into every cavity.” This precision dramatically improved fill accuracy. The plant’s quality manager notes that fill-weight variation shrank to nearly zero, meeting the company’s strict food-safety specifications. As one operator puts it, “It’s night and day – every pack looks identical now.” In addition, the YDSH-120 automatically applies the foil lid and seals it with uniform temperature and pressure. The result is an airtight, tamper-evident package every time. Industry experts emphasize that high-speed blister machines “ensure a consistent, secure seal that protects products”. In practical terms, the butter packs now ship with virtually no leaks or contaminants, improving shelf life and customer confidence.
Hygiene and Automated Cleaning
Maintaining hygiene on a butter line is critical. Under the old system, sanitation was a major headache: each changeover or regular cleaning required partial disassembly of the machine, and the process could take an hour of idle time. The YDSH-120 introduced an automated cleaning cycle and easy-clean components. “Our new machine’s design really prioritizes hygiene,” says the plant operator. For example, its stainless steel chambers and quick-release fittings allow fast sanitizing. In fact, Yundu stresses that “cleaning systems are vital” and that user-friendly, easy-to-maintain machines “can reduce downtime and improve overall productivity”. Here that proved true: cleaning that once took 2–3 hours per day now takes under 30 minutes. The frequent washdowns demanded by food safety regulations are now built in as a push-button cycle. This not only keeps the line hygienic but also frees operators for longer production runs. “We seldom stop the line anymore except for a quick spray-down – it’s much less of a production drainer,” reports the sanitary manager. Overall, the YDSH-120’s design meets strict food-packaging standards by minimizing human contact and contamination risks.
Seamless Integration and Support
Integrating the new machine into the plant’s workflow was straightforward. The YDSH-120 connected to existing conveyors and labeling stations with minimal modifications. “The mechanical and control interfaces lined up almost plug-and-play,” notes the automation engineer. Crucially, Yundu provided full installation support and training. A plant technician recalls, “Yundu’s service team was on-site for two days to calibrate the system and train our operators.” Yundu is known for a robust global support network – it maintains service centers in multiple countries to ensure local technical support. The customer’s maintenance lead explains that having Yundu support means spare parts and expertise are always available, greatly reducing downtime risk. As Bruce Fu of Yundu states, the company focuses on downtime reduction because in food manufacturing “downtime isn’t just costly – it can be critical”. This emphasis was reflected in the customer’s experience: since installation, there have been no unscheduled stoppages for the blister line.
Plans for Future Expansion
Buoyed by the YDSH-120’s success, the food company is already planning its next phase of growth. “We’re seeing demand climb even higher, and now we have confidence our packaging can keep up,” says the production manager. The company has placed an initial follow-on order for two more YDSH-120 lines to install next year. Yundu’s sales director reports that this customer’s project is a prime example of how automated packaging machines can “revolutionize packaging efficiency and product safety”. The commitment to additional orders reflects the company’s positive return on investment: they achieved break-even on the first machine in under nine months thanks to labor and waste savings. With three YDSH-120 machines, the plant will quadruple its butter tray capacity without adding shifts.
In summary, the upgrade to Yundu’s fully automatic YDSH-120 Blister Packaging Machine transformed the customer’s operations. What was once a slow, laborious line constrained by manual processes is now a high-speed, precision system. “Our entire outlook on production changed,” says the plant manager. “We went from constantly chasing deadlines to confidently meeting them every day.” Thanks to the YDSH-120, the well-known U.S.-based food company has dramatically improved throughput, quality, and hygiene – and it has a clear path to scale up further in response to market demand.
Double-sided Convex Forming Blister Packaging Machine FAQ
Transparency is the cornerstone of our Yundu team. That’s why below, you can find the most common questions and answers we receive surrounding our blister packaging machine.
A Blister Packaging Machine is an automated system that forms, fills, and seals pre-formed cavities—called blisters—using materials like plastic and foil. It ensures precise, hygienic, and tamper-proof packaging, commonly used for food, pharmaceuticals, and cosmetics.
Yundu’s YDSH-120 stands out for its high-speed performance, advanced servo control, and user-friendly automation. It can produce up to 180 trays per minute with exceptional fill accuracy and minimal downtime, ideal for high-volume food and dairy applications.
By upgrading from a semi-automatic to Yundu’s fully automatic system, a U.S. butter producer increased output from 35 to 180 trays per minute. The YDSH-120 eliminated manual feeding, reduced defects, and ensured consistent, hygienic sealing for foil-sealed butter trays.
Yes. The YDSH-120 can package various semi-solid and viscous products such as butter, cheese spreads, sauces, and creams. Its modular design allows easy adjustment for different cup sizes, tray shapes, and sealing materials.
The YDSH-120’s full automation minimizes manual intervention, requiring only one operator per line instead of several. This not only cuts labor costs but also improves consistency and reduces human error during production.
Built with stainless steel and quick-release parts, the YDSH-120 supports automated cleaning cycles. It meets strict food-grade standards, reducing contamination risks while allowing fast, efficient sanitation between batches.
Yes. The YDSH-120 is designed for smooth integration with existing conveyors, labeling, and cartoning systems. Its plug-and-play interface and digital controls ensure minimal installation time and quick startup.
Routine maintenance is simple thanks to accessible design and durable components. Yundu provides comprehensive operator training and technical support, ensuring long-term reliability and minimal downtime.
Yundu offers global installation, training, and after-sales service. Spare parts and technical assistance are available through regional service centers, ensuring fast response and continuous production support worldwide.
Most manufacturers recover their investment within 6–12 months. The YDSH-120’s speed, labor savings, and waste reduction lead to significantly higher productivity and cost efficiency, making it a smart long-term investment.
