Blistering Machine Operator at Sagar Vitaceuticals Nigeria Limited

Job Summary

• We are seeking an experienced Blistering Machine Operator with hands-on pharmaceutical manufacturing experience to operate, set up, monitor, and clean blister packaging equipment used for pharmaceutical products.
• The successful candidate will ensure that blistering operations are performed safely, efficiently, and in compliance with Good Manufacturing Practices (GMP), approved SOPs, batch packaging records, and quality standards.

Key Responsibilities

• Operate and monitor automatic and semi-automatic blister packaging machines for pharmaceutical products.
• Set up blistering machines according to approved batch packaging instructions and SOPs.
• Perform machine changeovers, product changeovers, and format adjustments.
• Ensure correct feeding and handling of tablets/capsules during the blistering process.
• Set and monitor machine parameters including forming temperature, sealing temperature, machine speed, pressure, and other applicable process parameters.
• Conduct routine in-process checks for:
  • Blister seal integrity
  • Correct tablet/capsule count
  • Product appearance
  • Batch number and expiry-date printing
  • Foil and PVC/PVDC alignment
  • Correct cutting and blister formation
  • Leak/seal quality where applicable
• Perform and document line clearance before commencing each batch.
• Verify that the correct product, packaging materials, batch number, artwork, and printed components are available before production.
• Monitor the machine continuously and make approved adjustments to maintain product quality and production efficiency.
• Identify and report machine faults, abnormal operation, product defects, and packaging deviations promptly.
• Perform basic troubleshooting and coordinate with Engineering/Maintenance for technical faults beyond the operator's scope.
• Carry out equipment cleaning, dismantling, assembly, and sanitation according to approved procedures.
• Maintain accurate production records, equipment logbooks, checklists, and batch packaging documentation.
• Ensure proper reconciliation and accountability of packaging materials, including printed and controlled materials.
• Minimize product damage, packaging defects, machine downtime, and material wastage.
• Maintain proper segregation and identification of products and materials to prevent mix-ups and cross-contamination.
• Comply strictly with GMP, Good Documentation Practices (GDP), safety procedures, and company policies.
• Immediately report deviations, non-conformances, damaged materials, or suspected quality issues to the Production Supervisor and/or Quality Assurance.
• Maintain cleanliness and good housekeeping around the machine and packaging area.
• Work closely with Quality Assurance, Quality Control, Engineering, Warehouse, and other Production personnel.
• Assist during machine qualification, validation, preventive maintenance, and troubleshooting activities when required.
• Participate in investigations related to packaging defects, machine failures, deviations, and customer complaints where applicable.
• Perform other duties assigned by the Production Supervisor or Packaging Manager.

Key Performance Indicators (KPIs)

• Achievement of planned packaging output.
• Machine efficiency and uptime.
• Reduction in blister rejects and material wastage.
• Accuracy of batch coding and packaging information.
• Compliance with GMP and approved SOPs.
• Accuracy and completeness of batch documentation.
• Effective and timely machine changeovers.
• Compliance with line-clearance procedures.
• Number of packaging deviations attributable to operator error.
• Proper reconciliation and control of packaging materials.

Qualifications & Experience

• 2–5 years of relevant experience operating blister packaging machines in a pharmaceutical manufacturing environment.
• Minimum qualification of SSCE/OND, with OND/HND in Mechanical Engineering, Electrical/Electronics Engineering, Pharmaceutical Technology, or a related field being an advantage.
• Previous hands-on experience with pharmaceutical blistering/packing machines is essential.
• Experience with tablets and/or capsules is highly desirable.
• Good knowledge of GMP, SOPs, batch packaging records, line clearance, and in-process controls.
• Experience with machine changeovers, format adjustments, cleaning, and basic troubleshooting.
• Experience with machines from manufacturers such as ACG, IMA, Marchesini, Romaco, Uhlmann, or similar equipment is an advantage.

Technical Skills:

• Blister packing machine operation and setup.
• Machine format changeover and adjustment.
• PVC/PVDC and aluminium foil handling.
• Tablet/capsule feeding systems.
• Heat sealing and blister forming processes.
• Batch coding and printing systems.
• In-process quality inspection.
• Basic machine troubleshooting.
• Equipment cleaning and line clearance.
• Good Documentation Practices.
• GMP and pharmaceutical packaging procedures.

Personal Attributes:

• Excellent attention to detail.
• Strong commitment to product quality and patient safety.
• Good mechanical aptitude and problem-solving skills.
• Ability to identify packaging defects quickly.
• Good communication and teamwork skills.
• Ability to work under pressure and meet production targets.
• Reliable, disciplined, and safety-conscious.
• Willingness to work shifts, weekends, and overtime when required.