What is Blister Packaging?

Blister Packaging Sample

What is blister packaging?

The “blister” may refer to many kinds of pre-formed transparent plastic cavities that are often used to safely package tiny items. The blister, or bubble or pocket, forms by heating and molding a sheet of plastic; it completely covers your product. It is common practice to place blister packaging on a display wall.

Polyethylene terephthalate (PET) or polyvinyl chloride (PVC) material makes up this packaging. Blister packs typically include a paperboard card on the back and a transparent plastic pocket, bubble, or hollow for the contents. The plastic or backing often has a hanging feature of different types. While traditional face seal blister packs include cardboard backs. The cardboard’s front has a plastic blister to protect the goods.

Blister packs are prevalent in pharmaceutical, electronics, and toy sectors because of their durability. These packs decrease packaging costs by eliminating unnecessary boxes.

What is the best material for blister packaging?

You may find blister packaging created from a variety of polymers, including PVC, COP, PCTFE, PVDC, and more. Polyvinyl chloride, or PVC, is the material most often used for blister packing. Using PVC is beneficial because of how cheap it is. To make blister packs, you can use PVC sheets ranging from 0.25 to 0.3 mm in thickness.

What are the different types of blister packaging?

Blister packs often come in the following varieties:

Face Seal Blister Packing

Plastic blisters are heat-sealed to cardboard backings and molded around products. This blister packing is cheap and used for mass-produced goods.

Full-Face Seal Blister Packing

The blister covers the products and card backing. Heat-sealing or sliding the plastic through plastic pieces on either side secures it to the card. This blister packing is stronger with corners that are harder to break and more appealing.

Full Card Blister Packing

This blister mimics the full-face seal blister in that it covers the whole card. Some flanges encircle it instead of being heat-sealed to the card. They slide the card into position, and sometimes they staple it as well.

Trapped Blister Packing

A trapped blister is similar to a blister pack, except it features a cardboard portion that matches the blister’s form instead of plastic. The plastic is then placed between two cardboard pieces. The upper card half is die-cut to match the product blister.

This blister packing is more cost-effective than others as it doesn’t use heat-sealing techniques. Tamper-proof as shredded front cardboard is visible. Because it hides the plastic, it improves the aesthetic as well.

Thermoformable Blister Packing

The most popular kind is the thermoformed blister pack. Thermoforming a plastic or polymer sheet into a moldable shape is the first step in thermoformable blister packaging. Food and medication are two examples of products that use thermoformed blister trays.

Clamshell Packaging

Clamshells are hinged plastic containers. Packing heavier products within is typical. This blister packaging is reusable. The hinged clamshell may be replaced with a two-piece plastic sheet design. The bottom support lets tri-fold clamshell products stand upright on shelf space.

Skin Packaging

Using a combination of heat and suction, this production method creates blisters. Actual items serve as the molds. As the product is between two heated plastic sheets, the air in the center is removed using a suction.

blister pack

Material Characteristics

The many polymers used to make blister packs include PVC, COP, PCTFE, PVDC, and many more. The material most often used for blister packing is polyvinyl chloride or PVC.

First and foremost, using PVC has a low price tag. The thickness of the PVC sheets used to make blister packs varies between 0.25 and 0.3 millimeters. Polyvinylidene chloride (PVDC) is used with polyvinyl chloride (PVC) sheets to improve the packaging’s barrier properties. This effectively blocks out both oxygen and water.

One more lamination option for blister packing is polychlorotrifluoroethylene. As a moisture barrier, PCFTE is its principal use. Water vapor penetration is the lowest of all polymers when it comes to PCFTE.

Copolymers and cyclic olefin polymers both have excellent thermoforming properties and make excellent blister packing. Blister packs with deep compartments may be made by blending COP with other polymers, such as polypropylene and polyethylene. These are essential for pharmaceutical packaging.

Manufacturers of blister packs also make use of cold-form packaging from polyamide, aluminum, and PVC. Here are some of the most prominent features of blister packs:

Highly Visible Product

Blister packaging makes the goods stand out. Customers can make decisions while purchasing goods because of this. A blister pack is a great way for people to see the actual pill or tablet before they take it. This helps greatly in the process of product identification.

Visible Tampering

The reuse of blister packs is somewhat challenging. After opening a blister pack, it becomes very difficult to reseal. It may also be necessary to use tools for cutting to open blister packs, according to their application.

UV Defense

You may limit the amount of UV light that enters the blister packing by adjusting its transparency. Metalized PVC extends the life of perishable goods by blocking 100% of ultraviolet light.


One of the best ways to protect your product from air and water is to use blister packing. Adding additional layers of polymers to the blister packaging manufacturing process improves the barrier qualities.

Protect Against Water

Whatever is within is safe from liquids like water and vapor thanks to the thermoformed polymer. But the back cover also determines the overall packaging’s resistance to water. Loss of water resistance occurs when the blister packaging’s back cover is a paper-based sheet.

Drop, Hit, and Scrape Protection

Holding a product in place and protecting it from drops or unintentional impacts are two functions of blister packing. Prevent scratches with the hard-outer polymer coating.

What products are suitable for blister packs?

Blister packs are often used for the following products:

  • pills, tablets, and capsules
  • dental floss, and toothbrushes
  • materials for writing and drawing (such as pencils, erasers, paper clips, and glue)
  • portable media players, headphones, and other electrical items
  • batteries
  • toys
  • fragile product components
  • brittle things like printer ink cartridges
  • hardware (nails, screws, bolts, nuts, etc.)

Blister Packaging Applications

Many different types of businesses rely on blister packing. Its primary applications are the food and pharmaceutical industries. Other than that, it’s a go-to for storing all sorts of office supplies, home repair equipment, gadgets, and more.

What machine is used to make blister packaging?

The blister packaging machine. Food and pharmaceuticals production facilities use it often. Plastic is the material of choice for blister packaging sheets. They have a long lifespan, are transparent, and are resistant to oxygen and moisture.

blister packing machine

Blister Packing Machine

The blister packing machine typically uses heat sealing to seal the blister to the liner material before closing the package. Finally, the blister cover, which acts as the heat seal layer, is activated to seal the seams of the pack.

Hot and cold forming methods are both possible with blister machines, and they can process common films including Alu/Alu, PP, PVC, PVDC, and Aclar.

Scroll to Top