Custom-Tailored Blister Packaging Products

Blister packaging, sometimes called card packaging, is a cost-effective method for packaging and marketing consumer products using a clear blister pack sealed to a decorative blister card. The full-color blister card, coated with a solvent or water-based coating is sealed to a clear PVC, styrene, PET, or RPET thermoformed blister.

Blister cards and blister packs are produced either as part of a combination run or as a dedicated run. Combination runs are the most economical because they spread the set-up costs and tooling over various customer cards printing on the same sheet.

Common uses for blister packaging include:

• Retail Shelf Packaging
• Ink Pens
• Razors
• Dental Floss
• Hardware
• Cosmetics

Some features of blister packaging include:

• Solvent and water-based heat seal coatings
• 4-color process printing plus PMS match colors
• Special match colors are available
• Photo quality offset printing
• Wide material selections including recycled stocks and various thicknesses
• Specialty die cutting

Common Types of Blister Packaging Include:

Face Seal Blister Packaging

A Face Seal Blister Card is a coated card that is printed edge-to-edge with a flanged and formed clear blister surrounding the product and heat sealed to the front of the card. 

This is a very common and cost-effective blister pack for smaller and lighter-weight retail items. It provides full product visibility, and full or partial product protection, great for hang hook displays. Office products like pens and paper clips, toothbrushes, and other lightweight cosmetics are often packaged in face seal blisters.

Full Face Seal Blister Packaging

A Full Face Seal Blister Card is similar to the Face Seal Blister but extends to cover the entire face of the card. This offers more durability and strength than the Face Blister. 

It too provides full product visibility, full or partial product protection, and even stronger for hang hook displays. Lip balms, cosmetics, fingernail polishes, and razors are typically packaged in full face seal blisters.

Trapped Blister Packaging

A Two-Piece Trapped Blister Card consists of two cards, with the blister flange trapped between them, and sealed together. Trapped blisters do always require heat so expensive heat-sealing equipment is not required. This offers even more durability and strength along with improved theft and damage protection. 

Trapped blister packaging provides full product visibility, full product protection, and is even stronger for hang hook displays than face seal blisters. Items like batteries, door locks, automotive replacement bulbs, and accessories are commonly packaged in trapped blisters. 

Clam Shell With Insert Card 

A clam shell is a thermoformed plastic package that has hinges and contains a fully printed card. This is premium packaging for heavier and more costly items requiring more durability, strength, and extended shelf life. 

Like the other types mentioned above, clam shells also provide full product visibility, full product protection, and are strong for hang hook displays. Items like saw blades, batteries, door handles, and locks are commonly found in clam shell packaging. Other plastic packaging options include Tear Resistant Blister Cards, Mock Clam Shells, 2-piece Clam Shells, and Tri-fold Clam Shells.

Skin Board Packaging

Skin board packaging also known as skin packaging is a low-cost method for displaying a product using a printed decorative backer board and a heated clear Surlyn film on the skin packaging.

Skin board is a specially formulated paperboard of corrugated board that is manufactured with microscopic pores to allow air to pass through during the process. After the board is printed with your custom graphics, a heat-activated adhesive is applied to the face of the board. Heated plastic film is draped over the product and the substrate, and a vacuum draws the film down tightly to the board and around the product to make a secure and attractive package. Wherever the hot plastic meets the adhesive, a bond is formed.

Innovative Packaging Solutions For Every Industry 

We design our products to meet the diverse needs of all types of industries, from pharmaceutical packaging to consumer goods. Whether you need custom blister packages, clamshell packaging, or skin board solutions, our packaging technology can deliver exceptional results. 

For clients within the pharmaceutical industry, we also offer primary packaging that ensures adherence, defense product integrity and compliance with all regulatory standards. We utilize thermoforming and vacuum-forming processes to precisely create trays, capsules, and unit dose packaging with secure and tamper-evident seals. We also have extensive expertise in folding cartons, laminated materials, and packaging machines to offer durable and sustainable packaging options for medical packaging, food packaging, beauty supplies, and more. 

Our focus on custom packaging solutions, paired with state-of-the-art packaging equipment, allows us to develop clear plastic blister packs, die-cut cartons, and protective packaging to look appealing while still offering security. 

Meet Your New Packaging Partner 

Transform your product packaging today with our custom packaging solutions. Our blister packaging experts combine cutting-edge packaging machinery and innovative packaging solutions to develop package designs that protect, enhance, and accent your products. Our custom-tailored solutions can ensure the secure and visually appealing results you are looking for. 

Call for a custom quote today at 919-614-3076 or reach out online to learn more about our packaging services and how we can collaborate with you to deliver packaging products that are sustainable, durable, and compliant!