As you browse the aisles of your local pharmacy or grocery store, you’ve likely noticed medicine, electronics, and various consumer goods enclosed in plastic “bubbles” on cardboard backing. This type of packaging is known as blister packaging or blister cards. In this 100-word overview, you’ll learn what blister packaging is, why it’s so commonly used, the materials blister packs are made from, the types of items packaged this way, the benefits and drawbacks of this packaging method, and more. With its visibility and popularity, blister packaging plays an important role in product presentation and protection. Keep reading to become better acquainted with this ubiquitous packaging type.
What is Blister Packaging?
Blister packaging, also known as blister cards or blister packs, refers to pre-formed plastic packaging used for small consumer goods, foods, and pharmaceuticals.
The blister packaging process involves sealing a product between a pre-formed plastic cavity and a printed card or foil. This creates a cavity in the shape of the product. The consumer can then push the product through the backing material to remove it from the package.
Blister packaging offers several benefits:
It protects the product from environmental exposure and contamination. The sealed plastic forms a barrier between the product and outside elements like moisture, oxygen, and dust. This helps maintain freshness and prevents spoilage.
It provides tamper resistance. The backing material is difficult to pierce or remove without leaving evidence, so consumers can easily see if a package has been opened or tampered with. This is important for foods, medicines, and other products where tampering could pose safety risks.
It allows for product visibility. The transparent plastic front provides a 360-degree view of the product so consumers can clearly see what they’re buying. This can influence purchasing decisions.
It facilitates product accessibility. Blister packs make it easy for consumers to access and remove the product through the backing material. The packs can also be designed for easy opening, with or without tools.
In summary, blister packaging offers an ideal solution for safely containing, protecting, and displaying a variety of products. With the range of plastics and backing materials available, blister packs can be tailored to suit the specific needs of any product. Their tamper-evident and product visibility properties provide benefits for both consumers and manufacturers.
The Benefits of Using Blister Packaging
Blister packaging offers several advantages over other types of product packaging. As a form of pre-formed plastic packaging, blister packs securely contain and protect products from external factors that could potentially damage them. Protection From Environmental Factors
Blister packs seal products in a sterile plastic cavity, shielding them from exposure to elements like moisture, oxygen, and contaminants. This helps prevent degradation and ensures maximum shelf life and product integrity. The impermeable plastic also provides an effective barrier against punctures, tears, and leaks.
Tamper Resistance
Blister packs are difficult to open without leaving visible damage, deterring tampering and product adulteration. The heat-sealed or adhered backing is hard to remove and then reseal without signs of entry, giving consumers peace of mind about product safety and quality.
Easy to Display and Stack
The rigid plastic blisters provide structural support for products, allowing blister cards to be attractively displayed on racks, counters, and shelves. Their uniform shape also makes blister packs easy to stack, saving space in storage and during shipping.
Cost-Effective
Blister packaging is an economical choice for many products. The manufacturing process is fast and efficient, and blister packs do not require the complex sealing equipment needed for other options like clamshells. They are also lightweight, reducing material and shipping costs. For these reasons, blister packaging is ideal for a wide range of consumer goods, medical devices, pharmaceuticals, and other applications where low cost and high volume are priorities.
In summary, blister packaging offers protection, security, display, and cost benefits that make it a versatile and appealing choice for many products. When selecting unique packaging ideas and method, blister packs should be considered as an option that balances product requirements with budgetary needs and operational efficiency.
Types of Blister Packaging and Blister Cards
Thermoformed Blister Packs
Thermoformed blister packs are one of the most common types of blister packaging. They are produced using a thermoforming process, where a sheet of plastic material is heated until pliable and then formed over a mold to create the blister cavity. The thermoformed blisters are then sealed to a cardboard backing to complete the blister card. Thermoformed blister packs can be made from a variety of plastic materials, including PVC, PET, and PETG.
Cold Formed Blister Packs
Cold formed blister packs are produced through a cold forming process using pre-made plastic sheets, without the application of heat. The plastic sheets are stamped using a die to form the blister shape. As the material is not heated during this process, cold forming can achieve more detail and depth. However, it also requires softer, more malleable plastics like PVC. Cold formed blister packs are commonly used for small consumer goods, cosmetics, and pharmaceuticals.
Carded Blister Packs
Carded blister packs, also known as blister cards, contain the blister-packed product attached to a cardboard backing. The blister packs, which can be either thermoformed or cold formed, are sealed to the cardboard to provide structural support and allow for shelf display. Blister cards are a popular retail packaging format as they provide high visibility of the product while still protecting it from damage, tampering, and theft. They are commonly used for small consumer goods, toys, electronics, and non-prescription drugs.
In summary, the three main types of blister packaging are thermoformed blister packs, cold formed blister packs, and carded blister packs. Each offers product protection and visibility in a retail-friendly format. Blister packaging continues to be a versatile and popular packaging trend choice across many industries.
Blister Packaging Materials and Construction
Blister packaging consists of two main components: a pre-formed cavity and a sealed backing. The cavity, also known as the blister, is commonly made of plastic materials such as polyvinyl chloride (PVC), polypropylene (PP), or polyethylene terephthalate (PET). These plastics are selected based on factors such as clarity, rigidity, chemical resistance, and cost.
PVC
Polyvinyl chloride is a popular choice for blister packaging. It is a rigid, clear plastic that provides good visibility of the product. However, it may not be suitable for products that interact with PVC. PVC blisters can be manufactured using a thermoforming or cold forming process.
PP
Polypropylene is used for products that are incompatible with PVC. It has good clarity and rigidity but is more chemically resistant and heat-tolerant than PVC. PP blisters are typically thermoformed.
PET
Polyethylene terephthalate is another alternative to PVC. It has strong rigidity and clarity, with good chemical resistance. However, PET is more expensive and difficult to thermoform compared to PVC and PP. PET blister trays are often cold formed.
The backing material, or lidding, is sealed to the blister cavity to complete the package. Common lidding materials include aluminum foil, coated or laminated paper, and coated or laminated films such as polyester, polypropylene or polyethylene. The lidding is sealed to the blister flange through a heat sealing process that fuses the materials together.
Proper blister packaging construction and sealing is important to ensure product integrity. When designed and manufactured correctly, blister packaging can provide an effective barrier against moisture, oxygen, and contaminants while showcasing the product. The choice of materials and quality of construction will depend on factors such as product compatibility, shelf life requirements, and cost.
Uses of Blister Packaging Across Industries
Blister packaging is versatile and used across many industries for a variety of products. Pharmaceuticals Blister packs are commonly used to package medications in the pharmaceutical industry. They allow for easy access to pills while keeping them securely sealed and organized. Blister packaging also provides tamper resistance and protects the potency of the medication. Each cavity in the blister pack holds one dose, so patients can easily keep track of their medication schedule.
Electronics
Blister packs are ideal for packaging small electronic components like batteries, USB drives, SD cards, and charging cables. The clear plastic allows customers to view the product while the cardboard backing keeps everything neatly in place. Blister packs also create a hanging hole so the product can be displayed on peghooks in stores.
Toys
Blister packs are popular for packaging small toys, figurines, trading cards, and other collectibles. The visibility allows children and collectors to see all parts and details of the items inside. The sealed cavities also help keep all pieces together and prevent loss or damage. Blister packs create an exciting unboxing experience as children pop out each toy.
DIY and Hardware
For DIY, hardware, and other home improvement products, blister packs offer an ideal way to package and display an array of small parts like nails, screws, nuts, bolts, hooks, and more. The clear plastic front makes it easy for customers to find the exact items they need while the cardboard backing keeps everything neatly organized and labeled. Blister packs also allow for efficient storage and can be hung on pegboards.
In summary, blister packaging is a versatile method used across many industries to safely and attractively package, display and distribute a wide range of products. Its tamper-resistant and moisture-resistant properties, combined with its low cost and visibility, make it an ideal solution for many types of items. Blister packs provide an excellent customer experience from the retail shelf to the home.
Conclusion
As we have seen, blister packaging is a versatile and innovative packaging method used for a variety of products. With its tamper-evident and theft-deterrent properties, it keeps products safe. The customizability of blister cards allows for branding and display of products at the point of sale. While more expensive than other options, blister packaging provides unparalleled product visibility and security. With responsible manufacturing, blister packaging can be an eco-friendly choice. For many items, blister packaging is the clear choice to protect products and connect with consumers. When thoughtfully implemented, it is a win-win for both manufacturers and customers.
