Blister Packaging

What is Blister Packaging? Create the Perfect Package with Plastic + Paper

With blister packaging, your product is nestled between a plastic cavity and a printed paperboard backing, also known as a blister card. Or you can create an All-Paper Blister made totally of paper. There are various methods to seal the packaging, but the most common method is via heat-sealing.

Blister Packaging =
A Plastic Cavity or Paper Tray Containing Your Product +
A Blister Card (Heat Sealed Together) to Form the PERFECT PACKAGE

How is Blister Packaging Created?

At Rohrer, blister packaging can be produced using three different manufacturing processes, each with unique features and benefits for your brand:

ezCombo®: Our innovative manufacturing solution where several different printed or plastic (thermoformed) packaging pieces are run together in a combo-run, saving your brand valuable time and money in the process.
Custom: Looking for a custom blister package designed specifically to fit your product, including all the “bells and whistles” your brand needs? Custom blister packaging provides brands with a premium look; however, it also comes with a premium price tag.
Stock: Our Stock Packaging Program includes a series of tooling for generic plastic packaging in standardized sizes, and styles to choose from. There are more limitations on packaging sizes/styles, but it is an economical, versatile, and streamlined way to get your product on retail shelves. Click here to see the wide variety of tooling for blisters, boxes, clamshells, rounds and folding cartons offered in our Stock Packaging Catalog.

What are the Benefits of Blister Packaging?

According to Markets and Markets, the blister packaging market is projected to top $34.1 billion by 2025, at a compound annual growth rate of 7.2%. Why do most companies choose blister packaging for their products? Let’s look at the benefits of blister packaging:

It’s a Branding Boost: The see-through plastic blister allows your product to be clearly visible. And the paperboard blister card provides ample billboard space to tout product features/benefits for consumers.
It’s Affordable: Want to get your product to retailers without breaking the bank? Then blister packaging may be ideal. The designers and engineers at Rohrer can help you develop a cost-effective production process for your blister packaging.
It’s Fast: Meet (or exceed) the retail deadline! Expedite your time to market with Rohrer’s blister packaging options.
It’s Secure: It’s apparent if someone has tried to open a blister package. That’s why it’s an ideal solution for products that need to be in tamper-evident packaging.

What are the Typical Types of Blister Packages?

Time to learn the lingo on blister packages:

Face Seal: This is the most common type of blister package. It includes a flanged thermoformed blister and a paperboard backing. The product is secured in the package by heat-sealing the flange of the plastic blister to the face of the blister card.
Full Face Seal: With a full face seal, the plastic blister covers the entire front (or full face) of the package. This provides the package with added durability and reduces the risks of bent corners on the blister card.
Mock Clamshell: Mock clamshells have the look of a full face seal blister, but also include a small flange around the perimeter of the package that notches together like a clamshell.

Trapped Blister: Popular in the club store market, a trapped blister is when the plastic is sealed (or trapped) between two blister cards, opposed to being sealed directly to a coated card. Trapped blisters are typically more tamper-resistant, and two blister cards allow for more billboard space.
ecoCombo® Blister: ecoCombo® is Rohrer’s ezCombo® program + sustainable packaging materials. It combines the speed, ease, and affordability of combination-run packaging with sustainable materials like post-consumer recycled thermoformed blisters and post-consumer waste paperboard blister cards and inserts.
All-Paper Blister: This is Rohrer’s latest sustainable packaging option. It’s made completely of paper, including the blister! You can print on more of the package surface and choose from a variety of substrates, including paperboard that is Sustainable Forestry Initiative® certified. Depending on design parameters and materials, the All-Paper Blister can be run utilizing our ezCombo® or custom packaging programs.

Holding It All Together. What About Heat-Seal Tooling?

Since blister packaging is the perfect combination of plastic and paperboard, we need to consider what’s holding it all together – a heat seal. Heat sealing the plastic to the paperboard blister card will be necessary, so heat-seal tooling and/or machinery are items to consider when designing your package.

Rohrer to the rescue! Our team has years of experience developing heat-seal tooling, with the ability to design/build the tooling you’ll need. We can fabricate tooling for use on most of the major manufacturers’ machines, and even some custom equipment, including:

Nesting Trays

Blister Chute and Card Rack
Profiled Heater Platen
Quick Connect Auto-Feed Tooling

And once your line is up and running, you can count on us to keep it that way. Replacement of damaged tooling gets our highest priority, and our technicians are on stand-by to troubleshoot any issues you may have with your heat-seal machinery.

Is Blister Packaging Ideal for My Product and My Market Niche?

Absolutely! Who doesn’t want to take advantage of the product visibility and protection that blister packaging provides? Rohrer has a large, diversified base of consumer product companies across many markets, including, but not limited to:

School and Office

Health & Beauty
Hardware
Electronics
Sporting Goods
Crafts & Hobbies

Toys

Let’s add your brand to the list! You’ll be in good company.

How Can I Create the COMPLETE PACKAGE at Rohrer?

Blister packaging is another way to STREAMLINE your packaging. Rohrer can create the thermoformed cavity or paperboard tray and blister cards/inserts for your product packaging all in one place. Heat seal and assemble. Ready to hit the road to retailers! Another way to produce the PERFECT PACKAGE at Rohrer.