Resources & Articles

Blister Packs

When are blister packs the right form of packaging – and why is Janco the team you should trust?

One of our most frequent manufacturing projects, thanks in large part due to their diversity and wide range of potential uses across several industries, are blister packs.

Regardless of whether you need a crash course in why blister packs might be the best option for your needs or want to know what sets Janco’s process apart, you’ll find answers below.

Here’s what we’re covering:

Types of Blister Packs

Ever wonder why you’d go with a traditional blister pack VS clamshell packaging?

Trying to figure out what type of blister pack is the right fit for your needs depends on several variables, from the product you’re packaging to the quantity that you need to manufacture.

While there are a ton of similarities in terms of benefits, there are also some essential differences that make each type of blister pack ideal for specific product needs. Here’s a quick breakdown of what sets different models apart.

Clamshell: empty clamshell blister packMost variations of blister packs use a cardboard backing, but a clamshell package is a bit different. Instead, two plastic pieces are hinged together in the thermoforming process, either at the side or at the base. This comes in handy in a variety of different ways, allowing clamshell packaging to stand upright on shelves when stocked in stores.

Our custom design process gives you the freedom to ensure the clamshell is aligned with your distinct needs, so the plastic may be heat-sealed closed on both ends or have a button to snap one side open and shut.

Most commonly, clamshells are used for sets that have more than one part, such as tool sets with several nuts and bolts or toy sets with multiple small parts. Generally, this type of packaging gives your product the same level of protection as any other blister packaging but works best for products that require more of a unique approach or need to be re-sealed after use.

Face Seal Blister Packs: This is what would be considered a traditional blister pack, where the plastic blister is designed and manufactured to fit your product (or several products) and then heat-sealed to a cardboard backing. This is ideal for packaging items made in large quantities because it’s fairly inexpensive compared to other options.

Trapped Blister Packs: This is the most similar to the traditional blister pack, but there are a few key differences. With a trapped blister, the name says it all – your plastic will be trapped between two pieces of cardboard. In addition to the usual cardboard backing, another piece is added over the front to cover the shape of your product using our custom die-cutting process. Because this doesn’t require blister pack heat-sealing methods, trapped blister packaging it’s generally a cheaper option.

Full-Face Seal Blister Packs: In another variation of the classic blister pack, the plastic surrounds both the product as well as the cardboard backing that supports it. Depending on your unique design needs, the plastic is heat-sealed to the card or slid through additional plastic pieces on each side. A full-face seal blister is typically used to enforce the strength of the blister pack packaging.blister pack packaging

Full Card Blister Packs: Similar to a full-face seal blister, the plastic on a full card blister is manufactured to cover the entirety of the cardboard backing. Instead of using the typical heat-sealing process, this uses flanges that wrap around to seal the plastic.

Need help selecting the right type of blister pack for your packaging needs? We’ll provide the guidance you need.

Get in touch

Common Industry Uses

Our team has served a wide range of industries over the years, offering custom solutions with the quality and precision that you depend on.

Even within each industry, there are multiple potential uses for blister packs. Below are some of the common uses we design and manufacture blister packs for in-house, but if the item you’re thinking of isn’t on the list, reach out! Our job is to find a solution.

Medical Industry Blister Pack Uses:

  • Medical devices
  • Medical implants
  • Medical and surgical instrumentation

Commercial and Industrial Blister Pack Uses:

  • Electronic devices and accessories
  • Automotive component packaging
  • Oral health products including toothbrushes and dental floss
  • Batteries
  • Screws, nails, nuts, and bolts
  • Protective cases
  • Ink cartridges

Blister Pack Benefits

Packaging your product can be as crucial as the manufacturing of your product itself. Packaging can determine a lot of variables, from how attractive your product looks on a store shelf to how protected your product is against wear and tear.

These are some key benefits to choosing a blister pack:

  • Protection – Not only do blister packs offer a high degree of protection during both transportation and storage, but you can also increase protection depending on the exact model and design that you choose.
  • Lightweight build – The lightweight design is great for handling, and it also means that you’ll benefit from lower transport costs, especially if you’re manufacturing and shipping large quantities of your product.
  • Unique design – The unique and wide-ranging design possibilities with blister packs mean that we can adjust the packaging to your exact needs. Our team offers direct consulting to help ensure we’re adding value to your packaging.
  • Easily recycled – In addition to so many practical benefits, blister packaging is also easily recyclable, so you can feel good about your packaging choices.

Blister Pack Materials

Our team can help with material selection based on the unique requirements of your packaging needs. In general, blister packaging is comprised of PET, PETG (polyethylene terephthalate), HIP (high impact polystyrene), or PVC (polyvinyl chloride) plastic.

Our engineering team can help you select the best materials for desired properties including:

  • Biocompatibility
  • Anti-static
  • Fire-retardancy
  • Impact
  • Abrasion resistance

How Blister Packs are Made

Blister packs are manufactured using our custom thermoforming process. Thermoforming involves taking a plain plastic foil (either PET, PETG, HIP, or PVC, as mentioned above) and transforms it into a three-dimensional shape by applying heat and air pressure. The plastic is molded into whatever shape is needed to bring your packaging solution to life.

Valued for being both highly customizable and cost-effective, custom plastic thermoforming at Janco allows us to manufacture single-use plastic parts with a wide range of potential uses. We frequently thermoform plastic in a variety of colors, densities, and thicknesses.

Our team also has trusted industry partners who offer injection molding services, which offer slightly different capabilities. Reach out to us directly to learn more.

Work with Janco for Your Blister Packaging Contract Manufacturing

Our team has been trusted as the go-to for quality contract manufacturing solutions for over six decades.
From the very beginning, it has been our mission to make the manufacturing process easy for you, with a team that has the experience to answer your questions and provide creative solutions for custom packaging needs.

With cutting-edge technology, an expert team of engineers and project managers, and a comprehensive quality assurance process, our team is proud to offer competitive pricing and unbeatable customer service.

Ready to manufacture custom blister packaging aligned with your unique product needs?

Reach out to Janco for the guidance and experience you need to get the job done right.

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