Sr. Blister Packaging Engineer

Aphena Pharma Solutions is growing, and we’re looking for an experienced Senior Blister Packaging Engineer to lead the design, validation, and continuous improvement of blister packaging systems for pharmaceutical products. This role is a key technical leadership position with real ownership, visibility, and influence across engineering, quality, operations, and customer teams.

If you enjoy solving complex packaging challenges, working in a regulated environment, and seeing your work move from concept to production, this role offers the chance to make a real impact.

What You’ll Do

Blister Packaging Design & Development

• Lead the design, review, optimization, and qualification of blister formats including PVC, PVDC, Aclar®, Alu-Alu, and cold-form structures
• Track and manage blister tooling portfolios and support RFQs for new applications
• Develop packaging solutions that meet stability, product protection, child-resistant, senior-friendly, and tamper-evident requirements
• Partner closely with Sales, Quality, Regulatory, and Manufacturing to align packaging designs with customer and regulatory needs

Equipment & Process Engineering

• Serve as the subject matter expert for blister packaging equipment, including thermoform and cold-form systems, tooling, feeders, sealing stations, and vision systems
• Support equipment selection, FAT/SAT, installation, commissioning, and optimization
• Troubleshoot forming, filling, sealing, print quality, and reject system issues
• Drive OEE improvements, scrap reduction, and throughput optimization

Validation & Compliance

• Author and review URS, FMEAs, protocols, reports, SOPs, and work instructions
• Ensure compliance with cGMP, FDA, EU GMP, ISO 9001, ISO 13485, and internal quality systems
• Support regulatory submissions, audits, and inspections related to blister packaging

Materials & Supplier Management

• Evaluate and qualify blister materials, suppliers, and tooling vendors
• Support material compatibility studies, seal integrity testing, and stability programs
• Manage technical communication with external vendors and contract manufacturing partners

Leadership & Mentorship

• Provide technical guidance and mentorship to junior engineers and technicians
• Lead cross-functional teams for packaging projects and continuous improvement initiatives
• Act as the technical escalation point for complex blister packaging challenges