A Beginner’s Guide to Blister Packaging

In brief, blister packaging is a method of packaging in which a sheet of plastic is heated and then moulded around the object being packaged. The thermoformed plastic produces a cavity or bubble, known as a blister. You will commonly see blisters attached to a cardboard back, although there are various forms of blister packs, all of which preserve the integrity of the object with bespoke covering. Blister packs come with many advantages, which we will discuss below.

But first, let’s take a look at the different types of blister packaging.

What are the Most Common Types of Blister Packaging?

The Face Seal Blister

The Face Seal Blister is the most popular form of blister packaging, and sees the plastic heat-sealed to a cardboard back. The cost-effective nature of face seal blisters makes them ideal for packaging small products produced at a high volume, such as toys.

The Full-Face Seal Blister

The Full-Face Seal Blister operates similarly to the one above, only the blister surrounds the cardboard back. This makes for more robust packaging and a generally nicer aesthetic.

The Full Card Blister

Like the Full-Face Seal Blister, the Full Card Blister surrounds the card. The difference, however, is that the Full Card Blister is attached to the back via flanges rather than being heat-sealed. The blister is folded tightly around the edges of the cardboard, holding it in place.

The Clamshell

Clamshell packaging omits the cardboard entirely, and is made with a single sheet of plastic divided into two halves by a hinge, allowing it to be closed shut. These might be designed to be reclosable, as is the case with containers of refrigerated foods, or they might be securely heat-sealed at the edges, requiring a sharp pair of scissors, knives, or trauma shears to open them.

How Blister Packs are Made & What They’re Made of

The plastic used to make the blister itself is typically PEV (polyethylene terephthalate), due to its clear transparency and robust qualities. The plastic is thermoformed into a blister with an aluminium resin tool before being placed into the sealing jig. The object or product is then inserted into the blister, and the cardboard backing, which has been specially printed to give it enhanced adhesive qualities, is fitted onto it. While in the sealing jig, the pressure of a hot metal plate works to seal the blister fully onto the card. The blister pack is then ready for distribution.

The Benefits of Blister Packaging for Your Business

Cost-Effective Transportation

Due to the lightness of the materials (cardboard and plastic) and the compact nature of the bespoke moulds, blister packs both weigh less and take up less space, which reduces transportation costs.

Individual Packaging

Blister packs remain a cheap and convenient method of packaging items individually, rather than in bulk. A good example of this is pharmaceutical products such as pills and lozenges.

Greater Protection

The way the plastic is securely moulded around the object ensures the integrity of its shape. This is especially helpful for items that might be easily damaged during shipping, such as action figures whose limbs could snap under pressure. The tightness of blisters ensure minimal movement of the product within the packaging.


Whereas a box can be opened and closed with little evidence to that effect, a blister pack by nature can’t be accessed without leaving behind physical signs. Given that almost all blister packs have to be irrevocably torn or cut into in order to be opened, this makes them very hard to tamper with. Pills, for instance, are individually sealed and it becomes immediately obvious if they’ve been accessed. Most consumable blister-packaged products (such as food or medicine) come with clear warnings instructing the consumer not to use them if the blister shows evidence of tampering.


The transparency of the plastic allows shoppers to get a better sense of what they are purchasing when compared to other forms of packaging, such as boxes.

What Products are Best-Suited to Blister Packaging?

  • Medication (tablets, capsules, etc.)
  • Toys/bobbleheads/figurines
  • Small electronics (chargers, headphones/earplugs, batteries, USB cables, memory sticks, etc.)
  • Toothbrushes
  • Stationary (pens, scissors, glue, pins, etc.)
  • Small DIY products (nails, bolts, screws, etc.)

Bespoke Packaging with Allegro Logistics

At Allegro Logistics, we pride ourselves on our family values and forward-thinking business ideals. We strive to instil a warm, friendly company culture into an industry that’s becoming more and more automated. The world of logistics is ever-changing, but with Allegro you be assured of a cutting-edge, hassle-free distribution of your goods. In teaming up with a specialised service provider like Allegro, manufacturers can focus on their products and trust in our expertise to get them in the hands of retailers and consumers as efficiently as possible. For more information on logistics and bespoke packaging, please don’t hesitate to reach out to our friendly team.

See more: 7 Tips for Improving Supply Chain Efficiency

See more: How to Run a Successful Subscription Box Business

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