Blister Pack

Blister pack is a term for several types of pre-formed clear plastic packaging used for small consumer goods. Blister packaging is an inexpensive option for creating packages that are durable, transparent, and tamper proof.

Blister packs are created by means of a form-fill-seal process. A form-fill-seal process means that the blister pack is created from rolls of flat sheet or film, filled with the product and closed (sealed) on the same equipment. Such equipment is commonly called a form-fill-seal machines (FFS machines) or blisterline.

Blister pack for general consumer goods.

Seal blister (cardboard card)

The most common type of seal blister consist of carded packaging where goods such as toys, hardware, and electrical items are contained in between a specially made paperboard and clear pre-formed plastic such as PVC.

The plastic, transparent so the item can be seen and examined easily, is vacuum-formed around a mold so it can contain the item snugly, and have room to be opened upon purchase. The blister packaging is attached to the blister card through a heat-sealing process that allows the product to be displayed in a wide variety of methods.

Clamshell blisters

The use of blister pack is somewhat limited to light weight items. For heavier items, one should consider using plastic clamshells. Clamshell blisters are typically used for theft-prone items like consumer electronics, it consists of either two pre-formed plastic sheets or one sheet folded over onto itself and fused at the edges. They are usually designed to be difficult to open by hand so as to deter tampering and pilfering.

The two blister halves are usually joined by high frequency welding machines. High frequency welding is a method of welding 2 thermoplastic parts, in which the surfaces to be joined are heated by contact with electrodes of a high frequency electrical generator. The resulting joint can only be broken with a knife or scissors. Hence, HF welded blister packs are perfect for heavy products and items attractive to shoplifters.

There are many other different types of clamshell packaging. Among them, those known as tri-fold clamshells deserve special mention. Tri-fold clamshells are designed to merchandise a product by hanging it on a peg wall, standing it on a shelf, or sitting it in a display. The three part design typically includes a triangular base that allows the clamshell to stand upright on a shelf.

This is a twin blister design. The two halves are connected by a hinge. This form of packaging has the advantage that the contents are fully visible, as with the seal blister between cards. The packaging is closed by the tabs molded into the blister. If a blister card is used it is inserted between the two halves of the pack. Folding blisters can be closed without special equipment.

Skin packaging

Skin packaging, or skin pack, is a type of carded packaging where a product (or products) is placed on a piece of paperboard, and a thin sheet of transparent plastic is placed over the product and paperboard.

The printed paperboard usually has a heat-seal coating. The plastic film is softened by heat and draped over the product on the card. Vacuum is sometimes used to assist a firm fit. The film bonds to the heat-seal coating on the paperboard. The skin-packed piece then may need to be cut into individual units.

Skin packaging somewhat resembles a blister pack, with the major difference being that the plastic surrounding the product is formed over the product, instead of being pre-formed.