Blister packaging providers need a number of supplies to keep their product-packing running smoothly. Blister packaging materials require machinery, sealants, plastics and printed card stock, not to mention things like printing inks, foil and plastic dyes. These materials and services can be purchased from suppliers or designed and assembled in-house.

You can save your blister packing company time and hassle by buying some supplies ready-made. Things like printed backings and specially formulated plastics take specific equipment and trained personnel to create, making it easier to purchase these goods and services. Before you start gathering your supplies for blister packaging materials, consider this:

1. If you need something unusual, or you'd rather make the plastics, backings and foils yourself, keep in mind that you'll need a lot of specialized equipment.

2. Certain industries, like food and medicine packaging, require you to use specific types of plastic to make your blister packs and clamshell packaging.

3. Specific types of blister packaging plastic may require custom orders or long wait times. These include opaque and specially colored plastics, as well as those with unique properties.

Action Steps
The best contacts and resources to help you get it done

Buy plastics for blister packaging creation

Plastics for blister boxes are generally molded into shape with heat, creating a bubble to protect your product from harm. The back of each blister package is created separately, usually with a cold process. Polyvinyl chloride (PVC) is the most common type of plastic used to create blister packages, because it is easy to mold and has very little water-vapor permeability. Other types include polyvinylidene chloride, CTFE films and polypropylene.

I recommend: Check out Emco Industrial Plastics for PVC and other types of plastic, or buy from Acme Plastics.

Find blister packaging card stock and backings

The back of blister packs, as well as the card inserts in clamshell packaging, often require special manufacturing to fit the size and design of your product. These backings can have images, text or colors imprinted on them to display your product to advantage. Blister pack and clamshell backs are available from most blister packaging suppliers, who will work with you to design and mass produce the perfect backing.

I recommend: Check out Clearwater Packaging's blister pack backings, or try Transparent Packaging's clamshell cards.

Get stock blister packaging sealants and machinery

Sealants for blister packs and clamshell packaging are often plastics applied and then melted together with a hot roller or press machine. Clamshell packaging can use this method or others, depending on the type of product and the safety factors involved. Food products, for instance, are often sealed with resin to ensure food safety.

I recommend: Buy blister pack sealant from Mitsui Chemicals America. Get a heat sealing machine to apply sealant from Blisterpak.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  Choosing the right type of plastic to create your clamshell packaging and blister packs is a difficult job. The type of plastic you use can vary depending on the industry, shape, thickness and opacity desired. Blister pack material suppliers can often help you decide which plastic will meet your needs. Some even offer CAD models to help you see a design's strengths and weaknesses.

While product packaging evolved, blister packaging materials became a popular way to show off and package products. The simple plastic-bubble design of blister packaging provides protection without concealing what the consumer is buying.

You can get great solutions for blister packs by ordering parts and putting together your own sets, or by arranging for blister pack assembly off-site.

When buying blister packaging materials, think about:

1. The right size for your blister packs, in all three dimensions: horizontal, vertical, and depth.

2. How long it will take to get your order shipped to you.

3. How you will attach the blister packaging materials, sealing the blister pack to the card backing or other material.

Action Steps
The best contacts and resources to help you get it done

Get blister package product testing

The first step in finding blister packaging solutions is to find out what you need. Evaluate your product to see how much protection is necessary. Some blister packs are just for show, but others are harder plastic to give additional shell to the product. Damage control consulting services can do product testing to help you determine what your product needs.

I recommend: The techs at CSS packaging will do product testing for you to see what kind of blister package is necessary. More general consulting services like MissionMicro and Tranzact also have information; these companies use high-tech methods to come up with blister packing and shipping solutions.

Arrange blister pack customization

You can outsource your blister packaging to professionals online. Give an outside packaging service your specifications, and they will take care of the blister packs, saving you a lot of time and energy in-house.

I recommend: Companies like JJ Packaging will customize your blister packs. Firms like Assemblies Unlimited will take your products and package them for you; check out the range of services online.

Try do-it-yourself blister packs

If you prefer to go it alone, you can get blister pack plastic materials online as well. Look at what's offered in bulk and choose the best deal, then assemble your own line to put your products together.

I recommend: P and P Inc. offers blister packaging samples. The Sharp Corporation also lists blister package materials available.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  Always keep an eye on the size of your product. You want the blister pack shell to be roomy, but not so big your item is swimming in it. You also want to think about how the blister pack makes your product appear; too much room can make your product look puny.
• •  Match the bubble and the card! When ordering your blister pack and card backing, make sure the two are compatible. Your card back usually has print that you want your customers to see. Make sure this isn't covered up by being mismatch.

Blister packing encases your product in a hard, clear shell made of plastic. This shell can be made of several different kinds of plastic, depending on how much protection you need from light, moisture and heat. The plastic shell gets a lid, usually made of aluminum, which is coated in a heat-activated sealant. This lid can be printed on one side, giving the transparent bubble a background.

Blister boxes are used primarily for pharmaceuticals, such as pills and tablets. A variation of blister packaging, called clamshell packaging, is often used to seal personal products, toys, and electronics. These blister packaging materials are an effective, economical way to send and store medicines and other consumer products.

1. Food products may need blister wrap packaging made from specific types of food-safe plastic, depending on where you manufacture and sell your product.

2. Blister packs can be made in many different colors, and with varying degrees of opacity. This is important when designing kid-proof packaging for medications and other hazards.

3. Clamshell packaging is usually molded to fit your product, providing a secure nest that will survive transport and rough handling.

Action Steps
The best contacts and resources to help you get it done

Use clamshell packaging materials for fragile consumer goods.

A clamshell blister package prevents your product from being crushed with a durable plastic shell and plastic or cardboard backing. This shell can be made out of moisture, heat or light resistant plastic to protect sensitive things like cosmetics or food products. Most manufacturers will help you decide which plastic works best for your product.

I recommend: Get stock clamshell packaging from Proform Packaging or let Valk Industries help you design a custom clamshell package.

Get blister packaging materials for medicines and pharmaceuticals

Blister packs are primarily used to package pills and tablets. Each tablet is usually encased in a clear plastic bubble with a foil backing, so it can be peeled or pushed through the foil side. The foil back is sometimes printed with a company logo, text, or graphics to correspond with the other packaging. The most common type of plastic used in pharmaceutical blister packs is polyvinyl chloride. This type of plastic is easily shaped and has low water vapor permeability.

I recommend: Get blister packaging materials basics from Jamestown Plastics, or check out blister pack options from Form Tight.

Purchase blister packaging machines to package and seal your product

Handling the blister packing yourself means renting assembly and sealing machines. These machines place the product in each bubble and seal the back in place, using a heat-activated plastic sealant and primer. The plastic sealant can be applied as part of the process, or by workers to save costs for smaller operations.

I recommend: Buy a sealing machine from Partner Pak, or use CPI's blister packing facilities to produce your product packaging.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  Depending on the type of plastic you use, companies working with polyvinyl chloride and other packaging plastics may need to register with the EPA due to the chemicals released during the plastic's heating.

Blister packaging is a popular way for companies to package their products. If you are considering using blister packaging for your product, you may be confused about all the different types of blister packs out there. Whatever your needs, consider learning the vocabulary of blister packs to help you make the right choices.

Action Steps
The best contacts and resources to help you get it done

Unit dose packaging

Unit dose packaging is required for use in hospitals and doctor's offices. This means that each unit of medicine has its own individual package. This makes the packaging a bit more secure.

I recommend: Learn more about unit dose packaging and see a picture from Avery Dennison.

Paperboard

Paperboard consists of several layers of paper that have been put together to create a sturdy, board-like product. It is sometimes used in blister packaging by placing the blister in between two pieces of paperboard, as in a package of batteries.

I recommend: See examples of paperboard packaging at JJ Packaging.

Clamshell

Clamshell blister packaging is when the product is placed between two plastic shells that open like a clam.

I recommend: See some examples of clamshell packaging from National Plastics.

Cold form foil

Cold form foil is often used in blister packaging for over the counter medicine. Individual pills are placed into a specially formed blister, then the cold form foil is applied over the back. This makes it easy for consumers to pop one dose out of the package at a time.

I recommend: See a picture of cold form foil as used in a medicine package at Amcor.

Thermoforming

Thermoforming is the process used to create the shape of the blister pack. A flat sheet of plastic is put into a machine, which heats it up to shape to a mold.

I recommend: Learn more about thermoforming, and see some pictures of thermoforming machines at the U.S. Department of Labor's Occupational Health and Safety Administration.

Polyvinyl chloride (PVC)

Polyvinyl chloride, or PVC, is often used to create blister packaging in addition to many other products. However, there is some debate about its use because the production of PVC releases toxins into the air.

I recommend: Learn more about PVC and the dangers of production from Greenpeace.