Blister Packaging
What is Blister Packaging?
Blister packaging is a type of packaging that consists of a clear plastic cavity or blister, which is then sealed to a printed paperboard card via heat and pressure. Since secondary sealing equipment is necessary for blister packaging, additional tooling is required. However these additional tooling costs are often offset by the reduced packaging costs and high speed packaging assembly.
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Blister packaging is ideal for projects that require high speed assembly, lower packaging costs and utilize the same packaging configuration for several years.
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There is also a blister packaging style known as form, fill & seal blister packaging. This is typically used for nutraceutical/ pharmaceutical products as the filling, forming and sealing is done in a cleanroom on one piece of equipment. Premier Plastics, LLC does offer this type of blister packaging. View the section of this website labeled “Form, Fill & Seal” for more information.
What is a trapped blister?
A trapped blister consists of a thermoformed clear plastic blister which is sandwiched between either a hinged/ folded card or two cards that are sealed together. This design provides a reasonable level of security, making it suitable for a wide variety of products.
What is heat seat tooling?
Heat seal tooling refers to the specialized equipment and tooling which uses heat and pressure to activate the heat seal coating in the printed graphic card. This process “seals” the blister to the graphic card.
What are the components required for a good blister seal?
There are several components necessary for a successful blister seal. On the equipment side those are: proper dwell time, temperature & pressure.
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On the heat seal tooling side those are: nesting trays that are flat/ level and a seal head that is flat/ level are free of debris or “pitting”.
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On the graphic card side those are use of the correct type of adhesive coating (this depends on what type of plastic the blister will be made from) and a consistent application of the heat seal coating.
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On the blister side minimal residual stress or absence of “cold forming” as well as consistent die cutting tolerances.
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You can test whether you are maintaining good blister seal integrity by taking one of your sealed blister packs and pulling the blister off the card. If there is visible and consistent paper fiber hairs embedded along the entire flange (sealing area) of the blister, as well as fiber tear on the graphic card, then a proper seal has been achieved.
Heat seal tooling typically consists of:
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Die sets or sealing bars with precisely engineered surfaces to ensure consistent and accurate sealing
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Heat transfer elements, such as heated dies, sealing bars, or platens, which apply controlled heat to the materials being sealed
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Pressure elements, such as pneumatic or hydraulic systems, which apply precise pressure to the materials during the sealing process
What is heat seal equipment?
Heat seal equipment refers to the machinery used to seal blister packs. There are many different types of heat seal machines. These range from a simple, single station shuttle style sealer to a fully automated, 8 station rotary sealing machine.
Which markets utilize a carded blister package?
Some of the many industries/ markets that utilize blister packaging are: Convenience, Consumer Goods, Electronics, Toys & Games, Hardware & Small Hand Tools, Cosmetics/ Personal Care as well as Automotive.
Does Premier Plastics, LLC offer blister sealing or contract packaging?
​Yes, Premier Plastics, LLC provides full turn-key packaging services. This includes the blister, card or fold over card, the heat seal tooling as well as the sealing & assembly via our heat seal equipment. We also provide turnkey packaging for clamshells & trays that go inside of a chipboard box or carton.
Is blister packaging the right choice for my products?
Blister packaging offers several advantages that make it a popular choice across various industries:
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Automation: The ability to automate the packaging filling & assembly process makes blister packaging an ideal candidate for medium to high volume projects.
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Tamper Evidence: As a result of the plastic blister sealing to the graphic card, any attempt to open or tamper with the product is easily visible by the naked eye.
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Cost-Effective: Due to the low packaging components costs, as well as the high speed sealing & automation, blister packaging is one of the most economical packaging options.