Reconcile coated tablets against blisters obtained, on a blister-count basis.
Blister reconciliation compares the coated tablets fed into a blistering line against the filled, accepted blisters actually recovered, on a blister-count basis rather than raw weight — since a blister card holds a fixed number of tablet pockets, and a shortfall in blisters maps directly onto tablets that never made it into saleable packaging.
This calculator first converts the total weight of coated tablets available into a tablet count, using the average coated tablet weight, then divides that by the number of tablets per blister to get the theoretical number of blisters the batch should yield. Comparing that against the actual number of blisters obtained gives both a % yield and a direct count of blisters lost.
Blister-count loss is usually easier for a packaging line to act on than a weight-based figure, since it maps directly onto rejected or short-filled blisters, machine jams, or tablets lost to inspection rejects during blistering.
Blistering is one of the last points where a genuine tablet-count loss can still be traced back to a specific cause — machine rejects for broken or chipped tablets, empty or partially filled pockets, and print or seal defects caught by inspection cameras all show up here. Reconciling on a blister-count basis, rather than weight alone, gives packaging teams a figure that maps directly onto the rejected units they can actually investigate on the line.
Convert the total coated tablet weight into a tablet count using the average coated tablet weight, then divide that tablet count by the number of tablets per blister.
Common causes include tablets rejected for being broken, chipped, or discoloured, empty or partially filled pockets, and blisters rejected for print, seal, or leak defects.