What is Blister Packaging? A Simple Guide

Have you ever bought medicine from a pharmacy and noticed how the pill comes in a clear plastic cover with a backing? Or maybe you have purchased small toy batteries or electronics that come in hard plastic packaging that is sealed in cardboard? If yes, you have already seen blister packaging in action. 

What is Blister Packaging?

Blister Packaging is a type of packaging that sandwiches a product between a clear, plastic cover (the blister) and some form of flat backing material. The plastic backing typically shaped to the contour of the product and formed to either a bubble or dome shape; while the backing material can be card or aluminum or a plastic film. 

Essentially, it is a protective blister packaging bubble with the plastic being a protective container for products while still allowing vision of the product by consumers. Blister packaging got its name from the dome or bubble-shaped plastic cover is like a blister that occurs when you get an injury to your skin.

How Does Blister Packaging Work? 

The process is quite simple. First, a sheet of plastic is heated and formed into the shape needed for the product. This created the “blister” or bubble part. Then, the product is placed inside this shaped plastic. Finally, a backing material is sealed to the plastic, trapping the product inside. 

The seal between the plastic and backing is usually very strong. This means the package stays closed until someone opens it on purpose. This helps the product to get protection from damage, dirt, and moisture. 

Types Of Blister Packaging

There are many variations of blister packaging each designed for different uses:

1. Face Seal Blister: This is the most common. The plastic is folded and sealed to the backing material, around the bypass. You will see this type of blister between your medications and small consumer goods.
2. Trapped Blister: The blister is trapped between two backing materials. This is a safer way to package and is often a desirable option for expensive items.
3. Full Face Seal: The blister is sealed to the entire backing – not just the edges, around the bypass. It provides the utmost protection and often sealer for medical supplies.
4. Clamshell Packaging: This is a clamshell form of blister packing. Similar, in that you have two plastic halves that close together like a clamshell, and this is used more often for larger items like power tools or electronics.

Where Do We See Blister Packaging? 

Blister packaging is everywhere! Here are some common examples of blister packaging you’ll find: 

1. Medications and pills: Blister packs are used for the majority of pills and tablets as it keeps the medication fresh; helps you count doses and can minimize contamination. 
2. Electronic devices: Batteries, memory cards, cellphone accessories, etc. are sold in blister packs primarily for theft prevention. The minimally packaged product deters thievery and reduces the damage that results from opening the packaging in the retail environment. 
3. Toys: Many small toys and collectibles are sold in blister packs, particularly in the stores you can actually interact with the toys. 
4. Food packaging: Certain types of readily available candy/sweet items like chewing gum and mints are blister packaging for freshness and ease of carry. 
5. Hardware: Screws, bolts and other smaller hand tools are also blister packed because it keeps things neat, clean and reduces the risk of losing items.

Benefits of Blister Packaging Machine

There are several advantages that blister packs can provide, and some of the major reasons businesses use blister packaging machine:

1. Product Visibility: Clear plastic allows customers to visually identify exactly what they are buying without the need of opening the packaging, which allows them to feel informed, confident, and trust the purchase regards to it being the correct product.
2. Protection: The sealed nature of the package gives decent protection against moisture, dust, bacteria, and impact which is crucial for food products and medicines.
3. Tamper Evident: Blister packaging provides the modern world with an easier means of identifying if someone had opened or tampered. This is much more relevant from a safety perspective in the case of medicines.
4. Storage space: Blister packs, as a rule, are flat; typically resulting in little change in size, allowing them to stack, be stored, packed, and efficiently transported.
5. Portion control: In the case of medicines, blister packs help support compliant behaviour by clearly specifying when to take doses, and what the recommended amount is.
6. Reduced theft: Blister packs, both as a product and not being able to remove it without damaging the package, create additional barriers for people trying to steal smaller items.

Disadvantages of Blister Packaging

Many advantages come with blister packaging, but there are also downsides:

1. Difficulty Opening: Generally people have trouble opening blister packs, especially if you are older or have limited hand strength. The term “wrap rage” has been introduced for the frustration people cause because they can’t get blister packaging open.
2. Environmental: Most blister packaging is comprised of plastic materials that are difficult to recycle. This represents waste that can cause damage to the environment.
3. Cost: Blister packaging can also be pricier than simple bags or boxes, especially in low quantities. 
4. Size: Blister packaging often increases the product size beyond what is absolutely necessary, causing more space to be wasted in shipment and storage.

Environmental Considerations

With the growing recognition of the significance of environmental issues, the packaging sector is beginning to offer environmentally-responsible blister packaging. Some brands are utilizing recyclable materials in blister packaging and existing packaging, while many others are making greater efficiency in packaging with the aim of using less plastic, and others are looking to see if they can utilize biodegradable materials that will naturally break down and decompose in time. The consumer can help by disposing of blister packaging properly, and also looking for products with less or more environmentally-responsible packaging whenever possible.

The Future of Blister Packaging

Blister packaging is still evolving through new technologies and innovations. Companies are creating easier-to-open blister packaging while achieving security and protection. Smart packaging that can track product movement or indicate insistently if the correct storage conditions have been maintained is also under development.

Conclusion

Blister Packaging is a simple yet effective means of protecting and displaying products. While it has some drawbacks, especially regarding environmental footprint and difficulty to open, it’s still commonly used, because it does a great job of keeping products protected, and visible.

Next time you pick up a medicine from the pharmacy or batteries from the shop, take a moment to appreciate the cleverness of blister packaging. It’s a small but important part of our modern world, where we expect a product to arrive to us safely, and exactly how we expected.

By having an understanding of blister packaging, we make better decisions as consumers, and we can appreciate the thought that goes into even the most basic aspects of product design.