Blister packaging is a type of packaging that goes through specific production stages and is also known as thermoformed plastic packaging. When blister packaging is produced, a plastic layer called the carrier layer is first extruded and rolled into a roll. The plastic layer taken from the roll is then shaped into the desired blister packaging shape using thermal forming devices. At this stage, since the blister is soft, any desired shaping can be easily achieved. After the shaping process is completed, the blister packaging is left to cool and becomes ready for custom blister packaging and filling. The blisters ready for filling are then prepared for labeling, i.e., the process of printing the brand name on them.
How Are Custom Blister Packaging and Filling Materials Sealed?
After custom blister packaging and filling, there are three methods for sealing the packaging.
After thermal processing and blister filling, aluminum foil or plastic film is applied to the packaging. This method should be planned during the design phase of the packaging. Thermal sealing is generally used for medium-sized packaging.
In the other method, thermal forming, a tight-fitting plastic lid is applied to the filled packaging either manually or by machine. Tightly fitted lids make the packaging resealable. This process is often used in custom blister packaging.
After blister packaging is done thermally, the lid is closed over the packaged product. This type of closure method is generally used in the packaging of food products that are consumed over a long period of time, such as medicines, food, or other products that can be filled. The adhesive flexible foil indicates whether the packaging has been tampered with, while the snap-on lid enables the packaging to be resealed.
Key Criteria to Consider During Thermal Forming Packaging
It is recommended that thermoformed blister packaging be purchased ready-made from a manufacturer specializing in contract blistering in the contract manufacturing sector. The reason for this is that a new mold must be prepared for each new production run. This is because a new mold is required for each new production run, which translates into additional costs for small businesses. However, this issue is eliminated with contract manufacturing, as the contract manufacturer always has ready-made blister packaging molds available.
Companies that consistently perform contract manufacturing at the same location use steel molds for this production. Steel molds are highly durable but also very expensive. For short-term productions, wooden, aluminum, or resin molds are used. While these types of molds are more economical than steel molds, their lifespan is limited. A significant portion of the cost of thermoformed containers is attributed to mold production costs. However, in long-term production of such packaging, it is rational to work with a new mold, i.e., to produce a new container outside of standard packaging. Otherwise, it is appropriate to use standard molds to minimize costs as much as possible. Printing is applied to these standard products according to the packaging consumer’s requirements. Therefore, it is recommended that the user request standard sizes.
How is the Design of Blister Filling Materials Made?
When blistering, the first thing to consider is that the corners of the packaging should not be sharp or pointed.
The plastic material used must be compatible with the product to be packaged. The plastic raw material should be selected according to the characteristics of the product to be packaged.
When performing custom blister packaging, the method of sealing the packaging must always be taken into consideration.
The selection of the lid for the blister packaging material should be based on the product, packaging, and sealing system.
Thermally formed packaging is printed using the dry offset method on 4 or 6-color machines.
The graphics printed on blister product packaging should not include complex photographs or similar applications.