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BLISTER PACKAGING - WHAT IS IT AND WHY USE IT?

By Hope Chan. Last updated: July 16, 2022

What Is Blister Packaging?

A blister packaging is made by heating up a sheet of plastic and molding it into custom shape so that a bubble or pocket is created to completely enclose the product inside.

Can I Use Blister Packaging on My Products?

I don’t see why not. Lots of products you see on the market are packed in blisters. Take a look and see if yours is one of them:

Toys
Food
Tablets
Tool Sets
Batteries
Stationery
Electronics
Beauty products
Others

Blister packaging offers not only protection for your products, it also helps you achieve the visual appeal you crave as well.

How Many Types of Blister Packaging Are There?

There are more than 10 types of blister packaging types. We categorize them into 4 groups based on their features:

Clamshell Packaging
Carded Packaging
Plastic Trays & Boxes
Flocking Blister Packaging

Keep reading and see if any one of them appeals to you.

Clamshell Packaging

Clamshell is probably the most commonly seen blister packaging type. Products ranging from edibles such as veggies, cookies, to non-edibles like figurines and USB flash drives can be packed in clamshells. Below are 3 typical clamshell packaging types:

1) Standard Clamshell / Clamshell Container

Basically it’s a container with 2 halves hinged together like a clam with snap-shut button for easy opening and closing.

Have ‘feet’ to stand upright or a ‘base’ to sit on the shelves
Single paperboard card for insertion into molded clamshell product (Optional)
Suitable for any products, light or heavy

2) 2-Piece Clamshell

2 custom-shaped blister packs (‘top & bottom’ or ‘front & back’ combination) put together and form a 2-Piece Clamshell.

Top & Bottom Combination: have a flat bottom and is able to sit on the shelves
Front & Back Combination: have a hanger
Suitable for any products, light or heavy

3) Tri-Fold Clamshell

2 halves hinged together and form a triangular bottom, which provides a solid base for products to stand upright.

Hanger is optional
Ideal for products that are unbalanced and/or heavy
Cost more than the Standard Clamshell or the 2-Piece Clamshell

Carded Packaging

Yep! You’ve guessed it. It’s got cards involved. Carded Packaging consists of both plastic blister packs and paperboard cards. There are 4 different ways they can be put together.

1) Slide Card Blister

It’s also known as Full Card Blister. The card and blister pack are separated and are of the same size.

Have 3 sides flanged so that the card can slid or be stapled into place
Customized to fit your product
More suitable for lightweight products

2) Trapped Blister

A Trapped Blister is a rigid plastic blister trapped and sealed between 2 paperboard cards.

Clear view of your product and tamper-proof
Convenient score area for easy opening
Die-cut area is on the top blister card
More suitable for lightweight products

3) Face Seal Blister

Front rigid plastic blister will be molded around the product and then heat-sealed to a single paperboard card.

Highly customizable regardless of the size or amount of items contained
Have exposed cardboard backing (Edge can be easily bent)
Inexpensive and generally used in large volume orders

4) Full Face Seal Blister

It’s quite similar to Face Seal Blister. The only difference is that the blister extends to the very edge so that it’s more durable and the edge won’t be so easily bent.

Offer higher perceived value and have a nicer look
Cost a bit more than the Face Seal Blister type

Plastic Trays & Boxes

Trays and boxes made of plastics fall into this category.

1) Plastic Insert Trays

A thermoformed blister tray that is put inside of an outer package so that the items contained can be well secured and protected by 2 layers of packages

See-through outer package design allows you to better showcase your products (Optional)
Suitable for any products, light or heavy

2) Packaging Trays

Custom thermoformed blister trays that can be used to hold products.

Round, square or rectangle, whatever shape or size you desire.

3) Plastic Boxes

PET/PVC/PP plastic boxes that come in all sorts of sizes, shapes and colors.

Flocking Blister Packaging

Flocking Blister Packaging is a plastic blister tray that have a thin layer of soft velvet-like flocked material glued to the surface.

Non-toxic & tasteless
Strong sense of three-dimensionality
Durable, sturdy and yet soft to the touch
Moisture-proof & friction-resistant
Bright colors, beautiful in appearance, easy to boost consumer desire

What Are the Pros & Cons of Blister Packaging?

Pros:

Since all plastic blister packs are thermoformed and each design is unique to the product contained, blister packs are highly customizable regardless of the size or amount of items contained.

Mass production of blister packaging products are quite cheap compared with other packaging solutions. And they are light, easy to transport.

Blister packages offer good protection for the items contained and because of the way they are sealed, blister packages also discourage unauthorized opening.

Plastic is highly malleable and can be easily molded into all sorts of forms, allowing your custom package to stand out and showcase the products contained.

Cons:

Not all plastic can be recycled.

In the case of Trapped Blister, Face Seal Blister and Full Face Seal Blister packaging, sealing tool is required for proper sealing of the packaging.