What Is a Blister Pack and Its Common Uses

A blister pack is a type of packaging that holds multiple items together in a single package. It's commonly used in the medical field to store and transport pills, capsules, and other medications.

The individual pouches in a blister pack are designed to be easy to tear open, making it simple to access the contents. This is especially important for people with dexterity issues or for taking medications on the go.

Blister packs are often used for medications that need to be taken at specific times of the day, such as birth control pills or daily vitamins. This helps ensure that users take their medications as prescribed.

A Blister Pack is a type of packaging that holds multiple items, such as pills, tablets, or capsules, in a plastic tray or pocket.

This type of packaging is designed to keep the items separate and organized, making it easier to dispense or administer the correct dosage.

Blister packs are commonly used for medications, but they can also be used for other small items like candies or even jewelry.

Each pocket in a blister pack is typically designed to hold a single item, and they are usually sealed to prevent tampering or accidental removal.

The plastic tray or backing of a blister pack is usually made of a durable material that can withstand handling and storage.

Blister packs are made from a variety of materials, with PVC being a popular choice due to its affordability and simple shaping process.

PVC, however, has a significant environmental impact, with chlorine and fluorine-based polymers releasing toxic acids.

This has led to a push towards alternatives to PVC in many countries with stricter regulations.

Blister packaging consists of four primary components: forming film, lidding, heat-seal coating, and printed information. The forming film and lidding are the key structural elements, contributing most of the packaging's weight.

The lidding foil is a crucial component, and the most common type is 20 μm hard tamper aluminum, which can be supplied pinhole-free from the producers.

A heat-seal lacquer is coated on the inside of the lidding foil, while a print primer is applied on the outside. This helps to seal the packaging and make it tamper-proof.

Printed information is also an essential component, used to apply labels, batch numbers, codes, and other essential information to the packaging.

Clear product display is also an advantage of blister packaging, as it helps shoppers see the product through the packaging, further aiding in their purchase decision.

Blister packaging is designed to safeguard the contents from outside contaminants, and the selection of films and lidding materials is guided by the product's sensitivity to light, oxygen, and moisture.

For instance, opaque materials such as aluminum are used to shield the product from light, safeguarding against UV-induced degradation. This is particularly important for products like tablets, which are almost always packaged in blister packs to keep them clean and uncontaminated.

If your product is susceptible to deterioration when exposed to the air or water vapor, blister packaging is an ideal solution that can help maintain your product's integrity until customer use.

Some products that require special protection include electronic goods and accessories, toys, and DIY goods, which can be vulnerable to breaking or have delicate parts that need to be shielded.

Here are some common types of products that benefit from blister packaging's protective features:

By choosing the right materials and design for your blister packaging, you can ensure that your products arrive at their destination in pristine condition, ready for use.

Blister packs come in various types, each designed to meet specific product needs. The most common type is the plastic blister moulded around the product and heat-sealed to a cardboard backing.

This type of blister packaging is fairly inexpensive and often used for large-volume products. I've seen it used for packaging small toys and candies.

There's also the full-face seal blister, which covers the entire product and card backing. The plastic is either heat-sealed to the card or slid through additional plastic pieces on each side, making it stronger and better-looking.

Unit Dose packaging of pharmaceuticals is a common use for blister packs. They provide barrier protection for shelf life requirements and a degree of tamper resistance.

In the US, blister packs are mainly used for packing physician samples of drug products or for over-the-counter (OTC) products in the pharmacy. In other parts of the world, blister packs are the main packaging type since pharmacy dispensing and re-packaging are not common.

A series of blister cavities is sometimes called a blister card or blister strip as well as blister pack. The difference between a strip pack and blister pack is that a strip pack does not have thermo-formed or cold formed cavities.

The main advantages of unit-dose blister packs over other methods of packing pharmaceutical products are the assurance of product/packaging integrity and the ability to create a compliance pack or calendar pack by printing the days of the week above each dose.

Blister packs are created by a form-fill-seal process, which means they are created from rolls of flat sheet or film, filled with the pharmaceutical product, and closed on the same equipment.

Additional reading: Alaska Packing List

Clamshell packaging is a type of blister pack that's often used for small high-value items like consumer electronics.

It's designed to be secure, making it difficult to open by hand to deter tampering. A pair of scissors or a sharp knife is usually needed to open it.

Care must be used when opening clamshell packaging, as it can result in injury if not done carefully. 6,000 Americans are sent to the emergency room each year due to injuries suffered in opening these packages.

Wrap rage is a common result of frustration when dealing with clamshell packaging that's difficult to open.

More than half of shoppers believe it's important to see a product through its packaging. This is where blister packs shine, providing a clear display of the product to aid in the purchase decision.

Blister packs are often used in retail due to their ability to display the product clearly through the packaging. This is a major advantage over other types of packaging.

The lid or backing material is often colored and designed to catch the eye of prospective buyers, making the product stand out on store shelves.

Blister packaging is a popular packaging method used in the pharmaceutical and cosmetic industries, but have you ever wondered how it's made? The process is quite fascinating and involves several steps.

The first step in making blister packaging is to form a heat-sealed blister using an aluminium resin tool. This process can be expensive, which is why it makes most sense to pack a decent number of products when using blister packaging.

The cardboard backing is then printed, using a special printing process which has adhesive in it. The adhesive melts under heat and pressure, allowing the plastic blister to stick to it.

The blister is then placed into a specialized part of the sealing machine, known as the sealing jig. The product is placed into the blister and the card is added.

The jig is rotated on a turntable and a hot metal plate is applied. Pressure is applied to the plate to seal the blister to the card.

The turntable is rotated again, and the final blister pack is removed and packed into outer packaging for distribution.

Blister packs offer several advantages and benefits that make them a popular choice for packaging various products.

Blister packaging is particularly effective at retaining the medicinal quality of the product, which is crucial for pharmaceuticals and other sensitive items.

Newly developed drugs often conflict with traditional packaging materials, but blister packs provide a compatible solution.

Complying with regulatory standards is also a breeze with blister packaging.

Here are some of the key benefits of blister packaging:

Blister packs are made from a variety of materials, but one of the most common is polyvinyl chloride, or PVC. PVC is a popular choice due to its affordability and simple shaping process, but it has some drawbacks, such as poor barrier properties against moisture and oxygen.

PVC is often used as the base material for blister packs, with a thickness of typically 250 μm (0.25 mm). This thickness is chosen to provide structural rigidity and physical protection for the pharmaceutical dosage form.

The water vapor transmission rate (WVTR) of a 250 μm PVC film is around 3.0 g/m per day, measured at 38 °C (100 °F) and 90% RH. This means that PVC films may not be the best choice for products that require high moisture protection.

To overcome the lack of barrier properties of PVC, it can be coated with PVDC or laminated to PCTFE or COC to increase the protective properties. This is often used in multi-layer blister films based on PVC.

PCTFE, also known as Aclar film, is a type of fluoropolymer that is renowned for its exceptionally low permeability to moisture and gases. It is often used as a laminate over PVC to improve barrier properties.

PCTFE films have the lowest water vapor permeation compared to all other plastic films used in blister packaging, with typical WVTR values of 0.06–0.40 g/m per day. This makes them an excellent choice for products that require high moisture protection.

Blister packaging is used for a wide range of products, including pharmaceuticals, nutraceuticals, and even food products.

Blister packs are commonly used for solid unit doses of medicines, keeping tablets or capsules separate and protected until used. They're also used for products like animal health products, cannabis, and medical devices.

You can find blister packaging in various forms, from face seal blisters and full face seal blisters to trapped blisters and clamshells.

Medical trays are made of a thicker plastic sheet, generally between 500 and 1,000 μg, which provides a solid base for packaging.

These trays are used for sterile medical devices and are typically found in hospitals.

The lidding film on medical trays is generally porous to allow sterilization and provides a peel-open feature.

This makes it easy to open and access the contents of the tray without compromising the sterile environment.

Blister packs suit a variety of products that need protection and organization. These products often have delicate or fragile parts that need to be kept safe.

Electronic goods and accessories, such as USB drives and headphones, are a great example of products that benefit from blister packaging. This type of packaging keeps them organized and prevents damage.

Toys, like the football figurines mentioned in the article, also benefit from blister packaging. Their delicate parts are protected, and they're less likely to get broken.

Stationery items, such as pens, paper clips, and superglue, are another type of product that's well-suited for blister packaging. This type of packaging keeps them clean and organized.

Batteries, toothbrushes, and dental floss are also commonly packaged in blister packs. This type of packaging keeps them clean and prevents tampering.

DIY goods, like screws, nails, and nuts and bolts, can also be packaged in blister packs. This type of packaging keeps them organized and prevents damage.

Tablets and capsules are often packaged in blister packs to keep them clean and uncontaminated. This type of packaging is almost always used for these types of products.

The following table summarizes the types of products that are commonly packaged in blister packs:

Blister packaging is used for a wide range of products beyond pharmaceuticals.

Nutraceuticals, which are dietary supplements that offer health benefits, are often packaged in blisters to keep them fresh and protected.

Animal health products, such as pet medications, are also commonly packaged in blisters to ensure they remain safe and effective.

Cannabis products are another type of item that may be packaged in blisters, often for medical use.

Medical devices, like small surgical tools, may be packaged in blisters to keep them sterile and organized.

Food products, including snacks and confectionery, can also be packaged in blisters for convenience and protection.

Blister packaging offers a range of options to suit different product needs. Face seal blisters and full face seal blisters are two such variations. Trapped blisters and clamshells are also available, each with its own unique features. Clamshells provide a secure and rigid packaging solution.

Blister packs are a safe and convenient way to take medication on the go. They're designed with tamper resistance in mind, making it harder for someone to open the package without being noticed.

This feature can be a lifesaver for people who may not be able to recognize signs of tampering in more traditional forms of packaging.

Blister packs also make it easy to take medication without having to open bulky containers or worry about spills during travel.