Blister packaging – it’s protective, tamper-evident, and a guaranteed way to build consumer trust thanks to the high visibility design.
But what exactly is it? What’s it made from? And what are the different types of blister packaging available? Ultragraph explains.
Contents:
- What is blister packaging?
- What material is blister packaging made from?
- What are common applications for blister packaging?
- What's the difference between a blister pack and a clam pack?
- Why choose blister packaging?
- What are the main types of blister packs?
- Is blister packaging recyclable?
- Cost-effective blister packaging at Ultragraph
What is blister packaging?
Blister packaging, also known as blister packs, are a type of pre-formed cardboard and plastic packaging solution.
It’s designed to be protective what’s inside during shipping, transport, and display, while also ensuring plenty of product visibility and brand advertising space.
What material is blister packaging made from?
Blister packing is typically made from two main materials.
For blister packs, the backing card is made from cardboard and coated with a bio-degradable adhesive. Alternatively, the paperboard can also be substituted for foil (if this is suitable for the product).
Meanwhile, the front moulded cavity referred to as the ‘blister’ is a thermo-formed plastic window made from either PVC (Polyvinyl Chloride) or a more recyclable option like PET (Polyethylene Terephthalate).
This results in a durable packaging solution with a solid back, offering space for instructions, branding, and user guidance, and transparent front to clearly display the product contained inside.
Ready to learn more? Call us on 01704 893938
What are common applications for blister packaging?
Blister packaging is most commonly used for relatively small physical products and other types of consumer goods, such as:
- Cosmetics: toiletry sets, face and eye masks, makeup samples
- Pharmaceuticals: pain relievers, contraceptives, allergy medications
- Electronics: earphones, charging cables, USB sticks
- Homewares: bottle openers, wax melts, nail clippers
- Hardware: screws, padlocks, small hand tools
Is blister packaging recyclable?
Yes, blister packaging is generally recyclable if made from cardboard and plastic.
Both elements (the cardboard and the plastic) require separation from each other, which happens naturally when a product is opened. Each element must then be appropriately recycled by ensuring they enter the relevant recycling waste stream.
Foil and plastic blister packaging however, can be extremely difficult to separate making it harder to recycle at home. While guidance varies between local authorities, most consumers will need to visit recycling centres or use dedicated take-back schemes to fully recycle this type of blister packaging.
What are the main types of blister packing?
Some of the most common types of blister packaging include:
Single card packs
Also known as face-seal blisters, single card packs are coated with an adhesive on the front, and the blister is stuck to the card when heat is applied, sealing the product into the card.
This is useful when the product is physically small as the backing card itself can be printed with the branding and useful information relating to the product.
Single card packs can also have a full-face seal blister design where the plastic extends all the way to the outer edges of the cardboard.
Example: Knife in single card pack
Trapped blister cards
At Ultragraph, we also manufacture trapped blister cards which are basically a folded card that has a heat seal adhesive applied to the reverse of the sheet.
The blister and product are then fulfilled, folded, and heat sealed to create a secure pack.
We also manufacture trapped blister cards with a pressure-sensitive adhesive which can be fulfilled by hand.
When the product is folded, the pressure-sensitive adhesive sticks to each other thereby creating a sealed package.
Example: A tube of superglue
Clamshell packaging
Clamshell packaging is a type of blister packing that features two halves of a plastic shell with a hinge at the bottom and locking mechanism at the top.
Once the two sides are folded together, they create a secure, closed container.
Example: Face paint packaging container
Weighing up your options? Call us on 01704 893938
What's the difference between a blister pack and a clam pack?
A blister pack is normally a plastic window or ‘bubble’ that's physically attached to a pre-printed backing card with a heat-activated adhesive coating.
The product is inserted into a blister and then pressed into position by a machine that deploys heat to adhere the blister to the card, securely sealing the product inside.
Clam packs (also known as clamshell packaging), on the other hand, are a complete outer plastic shell that join two halves together with a hinge at the bottom and a locking mechanism at the top.
They're normally clear and include a printed insert that's introduced into the packaging when the product is fulfilled. They're generally used on smaller runs and mainly fulfilled by hand.
Still unsure of the difference? Look at the table below!
Application
Blister packaging: Cosmetics, pharmaceuticals, electronics, homeware, hardware
Clamshell packaging: Food (fresh produce and takeaways), electronics, medical devices
Material
Blister packaging: Plastic (like PET and PVC) and cardboard or foil
Clamshell packaging: Plastic, such as PET and PVC
Suitability
Blister packaging: Medium to large production runs
Clamshell packaging: Small production runs
Fulfilment
Blister packaging: Predominantly automated
Clamshell packaging: Primarily by hand
Why choose blister packaging?
Unsure whether blister packaging is the most suitable solution for your product?
Established in 1973, Ultragraph is family-run business with extensive industry knowledge, meaning we know all the benefits of opting for blister packaging.
Some of the advantages of blister packaging include:
Protective
One of the most important aspects of any product packaging is that it adequately protects the item inside.
This is because the product can be exposed to drops, movement, and vibrations during shipping, transport, handling and display, resulting in potential damage.
With blister packaging, you can rest assured that the item within is securely held in position to help limit any damage.
As a result, using this type of packaging can help to reduce returns where the consumer has received the product in damaged condition
Builds trust
Consumers like to know what they’re buying.
With non-transparent packaging, businesses can sometimes face increased returns and complaints over misleading advertising – where the product described on the exterior of the packaging doesn’t accurately reflect the product within.
Whether there’s concerns over the size, quality, colour, or design of the product, the transparent plastic face of blister packaging helps to alleviate these worries and build greater customer trust.
Recyclable
Following the introduction of the regulatory scheme Extended Producer Responsibility (EPR), UK businesses are under increasing pressure to adopt more sustainable packaging practices.
Part of this framework requires obligated businesses to meet recycling targets, making recyclable blister packaging an incredibly helpful packaging solution for ensuring regulatory compliance in the UK.
Fast and efficient
Need packaging for your products as soon as possible? Thanks to high-speed automation, the blister packaging manufacturing process is fast and efficient, ensuring the packaging keeps up with product demand.
At Ultragraph, we utilise complete in-house production the latest tech - including the UK's first Heidelberg CX 104 – to print the cardboard backing for blister cards and apply the necessary heat-seal blister coatings in a single pass.
With everything needed to create high-quality blister packaging under one roof, we make the production process as quick and seamless as possible.
Tamper-evident
As each product is individually and securely sealed between plastic and cardboard (or foil), any product tampering is clearly visible through material punctures, helping manufacturers and consumers alike to easily determine whether the product has been used or tampered with in any other way.
Just like the transparency of the packaging, this tamper evident feature also supports greater consumer trust, and can therefore increase the likelihood of product sales.
Cost-effective
Whether you’re in the first stages of setting up a business and creating a product, or are looking to expand your existing product range, blister packaging can be an affordable way to achieve your goals.
While there may be some upfront costs to help cover setup (especially for custom designs), savings can be recovered by spreading this initial fee across the total production volume. This typically makes the per-unit price a cost-effective solution for medium to large production runs.
Branding space
Thanks to the cardboard backing, there’s plenty of space to incorporate branding. Whether that’s your business name, the product name, images of the product in use, or a summary of its features and benefits, this space is vital to grabbing consumer attention and increasing sales.
Call 01704 893938 to learn more about the benefits
Blister packaging areas to consider
While there are many advantages to using blister packaging, there are also some key areas to consider, such as:
Potential recycling challenges
Depending on the type of materials used, not all blister packaging is easy to recycle.
For example, not all plastic types can be recycled, while adhesive methods used to combine two different types of materials (such as foil and carboard) can make recycling them separately a challenge.
If sustainability and recycling is important to your business, the team at Ultragraph can help you to review all your blister packaging options and select a suitable option.
Varying costs depending on type
Yes, blister packaging is generally a very cost-effective packaging method.
However, the exact costs of this solution can also vary depending on the type of blister packaging. For example, single card is typically more affordable than clamshell packaging.
For a more accurate idea of blister packaging costs, we always recommend speaking to our knowledgeable team. We’ll take the time to understand your requirements and provide a clearer picture of potential costs.
Cost-effective blister packaging
For product packaging that’s both highly protective and visually appealing, blister packaging is a fantastic option – which is where Ultragraph comes in.
Whether you’re still in the process of designing your product or have already secured sales, our decades of hands-on experience, deep industry knowledge, latest tech, and problem-solving mindset can help you to find the most suitable blister packaging solutions.
We offer a full range of tailored blister card printing options, including:
- Custom boxes
- Standard single cards with heat-seal coatings
- Folded trapped blister cards
For extra impact, you can also add premium visual effect through specialist finishes like foil blocking, UV varnish, lamination and embossing.
To get started, simply give us a call on 01704 893938.
Alternatively, please feel free to fill in our online contact form!
We’ll get back to you shortly to learn more about your specific blister packaging requirements and how we can help.
