Blister packaging

27 February 2023

Overview of covered topics

Att. Blister-type packaging.

The thermoforming technology of plastics allows for the production of blisters, which are packaging perfectly tailored to the product. Blister packaging emphasizes the shape and highlights the essential qualities of the products while providing excellent protection against damage.

By reading the article, you will learn:

  • What are the production capabilities;
  • What information needs to be provided to estimate individual production;
  • What to determine before ordering blister production;
  • How long does it take and how much does it cost to create a prototype.

Types and applications of blisters

A blister is a contoured, rigid packaging typically made of plastic. It can be produced in any color, although most customers opt for clear blisters that allow consumers to see the products.

Read on to learn about the available types and colors of plastics used in blister production.

What products can be packaged in blister packaging?

Blister packs have a wide range of applications because it is possible to select specific plastic materials for their production. Customizing the composition and parameters of the plastic material allows for the extensive use of blister packaging, even in demanding industries such as food and medical, which require certifications.

Blister packs — available color options

Plastic materials are available in all the colors of the RAL palette, which makes it possible to produce blister packs in virtually any color. Most customers opt for clear blister packs, although black is also very popular. When ordering colored versions, it is important to keep in mind that most manufacturers have minimum material requirements, meaning there is a minimum quantity that must be ordered in a particular color.

Contact us to inquire about the minimum order quantity for blister packaging in your desired color.

What is the maximum size for a blister pack?

The first association is usually with packaging for tablets or pens, which are small items. However, blister packs are also an excellent solution for larger products such as household items, toys, or power tools.

Att. Blister packaging for a medical product.

In which industries are blister packs used?

Blister packs are used in various industries. They are most commonly used in the pharmaceutical industry for packaging medications and dietary supplements, as well as in the food industry for items like cookies. Thermoforming is also a widely used technology for producing packaging for cosmetics, toys, jewelry, office supplies, and the aforementioned power tools.

Why do customers and sellers like blister packs?

Blister packaging is popular because it not only facilitates product display in stores but also allows buyers to preview and evaluate products. Cosmetics or pens packaged in blister packs often sell better than those hidden in cardboard packaging. Additionally, blister packs serve a protective function, ensuring the safety of the final product during transportation.

The technology and cost of blister production

Blister packs are produced using thermoforming technology. This is a process involving heating a specific thickness and size of film, allowing the product to be shaped into the desired form.

Do you want to know the exact process of thermoforming and how blister packs are produced? Read the detailed description of the thermoforming technology.

Don't wait!

Tailor the technology to your needs to reduce plastic production costs.

Continue reading if you are looking for a manufacturer to fulfill your order or considering blister pack production in the future. Below, you will learn about the key stages of cooperation with Plastipol and find out how we can assist in fulfilling your order.

Design making and quotation

The first step is to provide a completed project or request us to create one for you. We create projects for a fee based on a 3D model, technical drawings, or a physically provided product that needs replication.

Packaging made with this technology using plastic materials can be permanently sealed or snap-fastened, which should also be determined during the project stage. It is also advisable to consider the method of product display in the store, for example, to design additional openings that enable hanging the merchandise.

The next necessary step for providing a quotation is to precisely define the production requirements.

What information is essential for a quotation?

  1. Does the content of the packaging require additional certificates, such as food contact certification;
  2. The thickness, color, and desired shape of the packaging;
  3. The purpose of the blister packaging – we need to specify the conditions it will be subjected to (weather conditions, temperature, heavy loads, chemicals, etc.).
  4. The method of sealing the blister pack (whether it should be heat-sealed, for example);
  5. The production quantity (number of units);
  6. The repeatability of the order (whether it’s a one-time production or if there’s an anticipated follow-up series).

Based on the provided information, our team will begin working on the production quotation. Acceptance of the project and the initial cost estimation of the order pave the way for the next stage, which is the prototype development.

Prototype manufacturing

Prototypes are created using a manual machine, even before the final mold is made. Most often, we produce several paid prototypes right away, and the cost of their production falls within the range of 500-800 PLN net per piece. The cost of making prototypes is always significantly higher than the subsequent mass production, due to the labor cost of the designer and operator, as well as the need to tailor the machine to individual orders.

Do you want to consult your project or the material for making blister packaging? Provide us with samples and take advantage of our free consultation.

Don't wait!

Tailor the technology to your needs to reduce plastic production costs.

Serial production

Acceptance of the prototype enables the start of mass production. The delivery time for the order is determined individually based on the production volume.

Why is it worth manufacturing blister packaging at Plastipol?

You can rely on technical support and assistance in preparing technical documentation, even if all you have is a concept. We introduce you to thermoforming technology, create the design, and help you select the appropriate material for its production.

When partnering with Plastipol, you can expect continuous support from a Project Manager who will ensure the proper execution of your order. They will coordinate all technical aspects and keep you informed about progress in real-time.

We care about the natural environment! The materials we use are recyclable, and we employ a closed-loop process in our production.

Do you have a project but want to change your current supplier? Contact us, and we will help you choose optimal processing parameters and ensure that the final product meets your expectations.

Adam Bernacki

Adam Bernacki

Technical director at Plastipol Poland. Popularizer of knowledge about plastics processing. Industry experience gained through education at Scandinavian polytechnics, work in global corporations in the plastics industry, and by managing technical issues in a Polish company. Specialist in plastics batch and mass production technologies. Author of articles and industry texts for clients in various industry sectors. Training Advisor.