Blister packaging is a type of packaging produced by heating a sheet of plastic and moulding it into shape to form a bubble or pocket the ‘blister’ that completely covers the product.
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A traditional blister pack is known as a face seal blister and has a cardboard back. The plastic blister is fixed to the front of the cardboard, to contain and protect the product. You can read more about the different types of blister packaging below.
The blister can be made in any shape a uniform shape to protect tablets, for example, or an unusual shape to protect a less consistently shaped product, like the football figurines shown in the image below.
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Some products typically packaged with blister packs include:
Blister packaging is all about protecting the product. If the product’s shape makes certain parts of it vulnerable—for example, the arm of the football figurines in the picture above—blister packaging can protect it in a way that a bag or box can’t.
Blister packs also keep products clean and uncontaminated, which is why they are almost always used to package tablets.
They are also tamper-proof. In other words, if someone has tampered with a pack of tablets (e.g. removed some of the contents), you’d be able to see that clearly from a break in the packaging.
The most common types of blister packaging are as follows:
Face seal blister
The plastic blister is moulded around the product and heat-sealed to a cardboard backing. This type of blister packaging is fairly inexpensive and so is generally used for products made in large volumes.
Full-face seal blister
The blister surrounds not only the entire product but the card backing too. The plastic is either heat-sealed to the card or slid through additional plastic pieces on each side. This type of blister packaging is used to make the packaging stronger (the corners are harder to bend, for instance) and better-looking.
Full card blister
Like the full-face seal blister, the blister covers the full size of the card. But rather than be heat-sealed to the card, it has flanges that wrap around it. The card is slid, and sometimes stapled, into place.
Trapped blister
A trapped blister is almost the same as a traditional blister pack but the plastic part that sticks to the cardboard has another piece of cardboard in front of it that fits around the shape of the blister. The plastic is then trapped between two pieces of cardboard. The top piece of card is die-cut to fit the blister where the product sits. As this type of blister packaging uses no heat-sealing methods, it’s cheaper to produce than those methods that do. This makes it more tamper-proof as it becomes obvious if the front cardboard has been ripped. It also looks better as it covers the plastic.
Clamshell
A hinged blister where two sides fold together to create a closed container. Clamshell packaging is explained in more detail below.
Clamshell packaging (also called clam packaging or clam packs) is a type of blister packaging. Unlike a normal blister pack, clamshell packaging doesn’t have a cardboard back. Instead, it has a plastic back which is hinged to the front of the packaging, either at the side or the base. Some versions are made so they can stand upright on shop shelves, while others are given a hole to be hung from racks. They might have a button to snap them closed, or be heat-sealed shut. The bubble can be evenly sized on the back and front or can be a different size and shape depending on the product inside it.
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Clam packaging offers the same kind of protection as any other blister packaging but works best for products that won’t really fit in a blister pack, or for sets that have several different parts. For example:
Advantages
Disadvantages
Question:What is a clamshell package?
Answer: Clamshell packaging has hinges that allow them to open like a clamshell. A clamshell package usually includes a hanger tab so it can be displayed on a store peg. Some clamshells have multiple hinges which gives them a flat base and allows them to be stood upright on a shelf. Retail products can be displayed for maximum visibility in clamshell packaging. High clarity and visibility allows consumers to see the product in great detail. Clamshells can also be formed to take on any shape and hold virtually any type of product. Clamshell packaging may not be perfect for every product, but its advantages make it a great choice for a variety of products from food and smart-phones to medical supplies and electronics.
Key Benefits
Tamper resistant
Good product protection
Forms a tight fit around product for no wasted space
Single-piece construction
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Question: What is a blister package?
Answer: Blister packaging is commonly used in the medical and pharmaceutical industries and many others. This type of packaging is excellent at sealing and keeping sterile pills and other pharmaceutical safe.
Blister packaging is also commonly used in retail packaging but usually small consumer goods, food, and electronics, etc… The main difference between a blister and a clamshell is that a blister doesn’t have a hinge. Blisters are usually attached to a paperboard card (header card) where the “blister” holds the product in place. Blisters are also great for showcasing products because their clarity leads to great visibility for the product.
Key Benefits
Blister card is ideal for communicating product information
Many packs can be made at the same time to hold different items
Cost effective to package single and low cost items
Question: What is thermoforming?
Answer: Blister packaging and clamshell packaging are made from a process called thermoforming. Thermoforming is the process of heating rigid plastic into a softened state, then cooling it back into a rigid state, around a mold, with the use of vacuum. This allows blister or clamshell packaging to be formed in to virtually any shape.
Question: Why should a manufacturer consider using a blister package or a clamshell package?
Answer: A blister or clamshell should be considered whenever there is a need to protect, contain, transport or merchandise an item.
Question: What is the best use of a clamshell package?
A clamshell has two sections, typically formed with a hinge on the centerline, which can fold over and attach to itself, creating an enclosed container. Clamshells are commonly used for food, smart-phones, electronics and much more. Clamshell packaging is usually associated with higher value items. For example, high end golf balls may come in a clamshell package while an inexpensive household 9V battery would typically be packaged in a blister package.
Question: What is the best use of a blister package?
Answer: A blister is a single, vacuum-formed shell that can contain and merchandise a consumer product, after it’s sealed to a header card. Blisters are commonly used on consumer product packages that have a relatively low value. A tape measure is frequently packaged in a blister package while an expensive automotive part may be packaged in a clamshell package.
Question: Are there any size limitations to clamshell or blister packaging?
Answer: Clamshell or blister packaging can have little restrictions on size. Limitiation on size will be determined by machinery and tooling. Most consumer and industrial products can be accommodated, particularily, if they are of the size and weight that can be hung from a display peg.
Question: What is a normal starting quantity for clamshell packaging or blister packaging?
Answer: 5000 units is usually considered a satisfactory quantity justify the expense of tooling and design; however, a high value product be justified at just 1000 or fewer units.
Question: What kind of plastic is used in clamshell packaging or blister packaging?
Answer: There are several types of plastics available for thermoforming. Most clear packages are formed using pvc, rpet, petg and styrene, but there are many choices when it comes to plastic selection:
Question: How long does it takes to make clamshell packaging or blister packaging?
Answer: Thermoforming cycle times of vary, depending on the thickness of the plastic, the size of the mold, and the type of machine it’s running on. A machine can make thousands to tens of thousands of clamshell or blister packages on a single machine.
Question: What are the steps to create blister packaging & clamshell packaging?
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