Introduction
Blister packaging is a type of packaging that is used to protect the products and is enclosed in a transparent, sealed cover that makes it easy to see the product and also helps in increasing the shelf life of the product. It is used in packaging of pharmaceutical products, electronics, foods, and other small or daily use products. The most important use of blister packaging is that it enhances safety, increases product visibility and enhances shelf life through a protective and easily identifiable layer. However, where is blister packaging most commonly used, and why has it become so popular? In this article, the author discusses the use and functions of blister packaging, the classification of blister packaging, the benefits of blister packaging, and how blister packaging is used in industries in today’s packaging world.
What is Blister Packaging?
Blister packaging means placing a product in a blister pack which is a molded cavity covered with a transparent plastic film or aluminum foil. This packaging style employs PVC, PET, or aluminum to form a protective shield that will shield the product from influences from outside. Blister packaging is most frequently used for tablets, capsules, and other pharmaceuticals, electronics, and cosmetics, where visibility and protection are important.
In blister packaging, one forms a depression in the blister pack, that would allow it to encompass the product, then covers it with the lidding material, normally a plastic film, aluminum foil, or both. Manufacturing processes of blister packaging include forming, filling, sealing, and cutting and provides a barrier against moisture, contaminant, and shock in addition to aesthetical appeal to the product. From the protection of drugs to offering theft proof hinged covers for electronics, blister packaging plays a significant function in many fields.
Blister Packaging Methods
Thermoforming
Blister packaging is a thermoforming process where a plastic film or sheet is heated to make it flexible before being shaped by high pressure (4-8 bar) into the cavity of the packaging. The formed mold is then cooled to a temperature that enables the plastic to maintain the formed shape once the mold is opened. For more complicated shapes or for larger ones, an “assist plug” is utilized to guarantee equal wall thickness. Thermoforming is commonly used for packaging small objects such as tablets, since it is quick, effective and forms a clear, strong barrier.
Cold Forming
Cold forming involves placing an aluminum based laminate film in a mold and applying pressure to form a blister cavity which serves as a good barrier to moisture, oxygen and light. This process is most suitable for products that need to be stored for a long time, for instance, medicine since it protects the product from the environment. However, cold-formed blisters are opaque and are larger in size, which affects the attractiveness of the product and the utilization of packaging space. However, cold forming is crucial for products that require maximum protection as they are very sensitive.
Thermo Cold Forming
Thermo cold forming is a process that has the advantages of both thermoforming and cold forming processes. In this combined process, the product is first wrapped in thermoforming to form a tough, transparent first layer. This is then succeeded by a cold-formed outer layer that provides additional barrier properties to the material, thus providing maximum barrier against moisture and oxygen. Thermo cold forming is ideal for products that need to be seen and protected at the same time, and as such, thermo cold forming is the perfect package for high-sensitivity products, especially pharmaceutical products.
Types of Blister Packaging by Material
The selection of materials for blister packaging machines is determined by the specific requirements of different industries and type of blister packaging desired. Below are the most popular and frequently used materials in blister packaging along with their merits.
PVC (Polyvinyl Chloride)
Because of its outstanding transparency and excellent barrier qualities, rigid PVC is the most preferred material for blister packaging. It offers adequate protection from outside interference such as moisture, humidity, and contaminants, which makes this material suitable for both pharmaceutical and consumer packaging. PVC is also low cost and economically effective, making it an ideal choice for mass production of packages where cost considerations are important.
PET (Polyethylene Terephthalate)
PET boasts a reusability that makes it a sustainable solution for blister packaging. While it may lack some of the barrier strengths possessed by PVC, its environmentally friendly attributes have made PET and polypropylene more popular in industries with a focus on eco-friendliness. High clarity is also guaranteed, which is crucial for product packaging in retail settings where visibility and display are key factors.
Aluminum Foil For packaging items like medicines that require high levels of protection, lidding film made from aluminum foil is ideal. Aluminum has excellent barrier properties and forms a tight seal that protects against moisture, air, and light. This makes it suitable for safeguarding sensitive products, such as tablets and capsules, where product efficacy and stability are crucial.
PVDC Coatings (Polyvinylidene Chloride)
PVDC coatings are applied to plastic films, such as PVC and other materials without chlorine, to enhance their barrier properties. This material is ideal for packaging products vulnerable to moisture and oxygen, as it provides an extra layer of protection. PVDC is commonly used in pharmaceutical blister packaging to ensure the extended safety and usability of the products.
Additional Blister Packaging Types
Blister packaging can also come in different forms, including hinged blister packs, where the blister and backing are joined by a hinge to create a reusable package. These types of packs are common in electronics and other consumer goods, as they provide added convenience for the end user while maintaining product security and visibility.
| Material | Pros | Cons |
| PVC (Polyvinyl Chloride) | Outstanding transparency, excellent barrier qualities, low cost, suitable for mass production, protects from moisture and contaminants. | Limited environmental sustainability, potential impact on eco-friendly initiatives due to PVC production. |
| PET (Polyethylene Terephthalate) | Reusable, sustainable, environmentally friendly, high clarity ideal for retail display, growing popularity in eco-conscious industries. | Less effective barrier compared to PVC; lacks some of the protective strengths needed for sensitive items. |
| Aluminum Foil | High protection level, excellent barrier properties, forms a tight seal against moisture, air, and light; ideal for sensitive products like tablets and capsules. | Opaque, limits product visibility, larger blister card sizes needed, slower production process in cold forming. |
| PVDC Coatings (Polyvinylidene Chloride) | Enhances barrier properties of films, provides extra protection against moisture and oxygen, extends product usability; commonly used in pharmaceuticals. | Adds extra cost to packaging, less transparency, specific use limited to barrier-enhanced needs in pharmaceuticals. |
Advantages of Blister Packaging
Product Protection and Shelf Life
Blister packaging machines offer optimum protection to products, especially those prone to defects like moisture, light, and contamination. In the packaging industry, blister packs made from aluminum foil and PVC materials create a barrier that enhances the shelf life of products, making them ideal for medicines, small consumer goods, and other perishables. This barrier provides added protection without compromising product safety or effectiveness, making blister packaging a preferred choice in sectors where product quality is paramount, particularly to comply with drug administration standards.
Cost Savings and Convenience
Blister packaging machines are not only fast but also economical to use. By reducing the need for additional protective materials, such as plastic bags or extra cartons, they lower packaging costs effectively. This contributes to lower price points for the end products, making them competitive in the market. The smooth appearance of blister packs allows for easy stacking and storage, which benefits space and supply chain management in warehouses. Additionally, blister packaging is convenient due to its easily tearable edges or specifically designed ‘push-through’ feature, which is particularly useful for pharmaceuticals.
Enhanced Product Display
Enhanced Product Display A significant advantage of blister packaging machines lies in enhanced product display. Transparent shells and customizable formats allow shoppers to see the product directly, providing a strong advantage for advertisements. Blister packaging can also be branded and labeled, adding promotional value, drawing attention in stores, and enabling brands to convey important information about low-cost solutions and product benefits directly to consumers.
Applications of Blister Packaging
Pharmaceutical Industry
Blister packages, especially pharmaceutical blister packs, are primarily used in the packing of tablet, capsule, syringe along with its other medical packing by blister packing machines segmented and made available in the pharmaceutical industry. The advent of this solution also allows patients to maintain adherence to their medication schedule, often times with the blister that is marked with the days of the week. Because blister packs are safe and resistant to tampering, they are essential in pharmacies and other health structures because they guarantee patient safety, as well as the legal standards of the industry.
Food Industry
Blister packaging machines are used in the food industry as well for snacking packs such as candy, chewing gum, and chocolates. The convenience of this type of packaging is that it is inexpensive and clearly shows what is inside. Blister containers help keep food products dry which increases their useful and storage life period. Blister packages are cost-effective, aesthetically pleasing, and ensure the product remains intact while being suitable for small products with high demand rotation.
Electronics Industry
In electronics, blister packaging machines are employed to form a clamshell packaging of items such as flash drives, batteries, and trinkets. This type of packaging protects products from physical harm and theft while at the same time improving the aesthetic value. Electronics blister packs are normally very hard and offer a clear view of the product through a transparent plastic shell, enabling the customer to make a purchasing decision without having to open the pack, which is usually the case in most shops.
Personal Care and Household Goods
Blister packaging machines are common in cosmetics, toothbrushes, razors, and other home products. This type of packaging helps to prevent items from being tampered with or contaminated and get to the consumers in good condition. For the personal care products blister packaging is more convenient, hygienic and attractive to the consumer hence making the shopping experience more enjoyable.
How Does a Blister Packaging Machine Work?
Heating and Forming
The forming process begins by heating the plastic film or sheet, typically made of materials like PVC or PET, until it reaches the required temperature. This heated material is then shaped into cavities through vacuum or pressure forming. A critical aspect of this stage is constructing the ‘blister’ shape that will securely hold the product. PVDC or other polymers are often added to some machines to enhance the water vapor barrier properties. This heating and forming process allows each compartment to be individually shaped, ensuring a secure and protective fit for the packaged items.
Filling and Sealing
In order to complete the blister packages, prepared spaces in the pockets are loaded with the product: tablets, capsules, miniaturized electronic devices, or even large items like foodstuffs. Quality machines have a mechanized filling component which streamlines and enhances the filling process—the accuracy and efficiency of such functions are important as they are the key in preserving the quality of the product. Blisters are then covered with lidding material cover for protection against water, air, light, etc. This lacquer cover is a combination of aluminum foils and adhesives. This action is highly important in the case there is a need for contamination free and sterile packaging which is particularly the case in the case of pharmaceutical products.
Cutting and Finishing
Towards the end, completed and sealed blister packs are divided into individual units or sheets. Some equipment is capable of flexible deployment parameters which allow for the production of different sizes and configuration of packages, be they blister cards for medicines or clamshells for electronics, or even cardboard designs. During cutting and finishing processes, clean edges are produced on the surface making it easy to use and storage of the finished blister packs. After this stage, the blister packs are prepared for shipments and sales which are long-lasting, protection, and attractive uses.
How to Choose the Right Blister Packaging Machine
Selecting the Ideal Blister Packaging Machine for Different Applications
The selection of blister packaging machine is not only based on the characteristics of the product but also on the application requirements of the machine. Below are some common application types and the recommended packaging machines for each:
1. Pharmaceutical Packaging
In the case of pharmaceutical products such as tablets, capsules, and medical devices, the blister packaging machines should provide accurate filling and sealing features as well as hygiene standards to ensure quality patient care. Key requirements include:
- Precise Dosing and Tamper-Evident Sealing: Guards against the wrong dosage and also prevents the container from being opened by unauthorized persons.
- High Cleanliness and Automated Controls: Meets industry standards and does not allow cross contamination.
Recommended Machine:
High-Precision Automated Blister Packaging Machine: Applicable to high speed, high accuracy production line of pharmaceuticals to guarantee the safety and wholeness of the products.
2. Electronics and Small Tools Packaging
For small items like batteries, electronic components, screws, etc., the packaging has to be strong and difficult to open, and this is done using clamshell or rigid blister packs.
- Impact Resistance and High Transparency: Ensures that the packaging is safe for the product but at the same time the consumer is able to see the product.
- Reinforced Sealing Design: Improves the product’s ability to withstand shock during transportation.
Recommended Machine:
Rigid Blister Packaging Machine or Heat-Seal Blister Machine: Provides long-lasting and secure packaging solutions with relatively good visibility.
3. Food Packaging
When it comes to food products such as candies or chewing gums, speed of filling is critical, as well as the materials used.
- Efficient Packaging with Moisture and Oxygen Protection: It utilizes aluminum foil or PVDC-coated films to enhance the shelf life of the product.
- High-Speed and Automation: Ideal for high turnover production lines to cut on labour expenses while at the same time improving productivity.
Recommended Machine:
High-Speed Blister Packaging Machine: Perfect for high turnover food preparation, the flexibility of using different materials to suit the preservation requirements.
4. Other Specialized Product Packaging
In this case, for some specific industries or non-conventional products such as cosmetics, or auto spare parts, packaging may have to be unique.
- Flexibility and Multi-Functionality: Flexible in the sense that it can accommodate packaging of different sizes, shapes and material.
- Customizable Design: May require special shapes or other protective elements.
Recommended Machine:
Multi-Functional Blister Packaging Machine: Flexible in terms of shapes and materials that can be used, suitable for various industries.
Leading Blister Packaging Machine Brands
1. SED Pharma
Leading Pharmaceutical Equipment Manufacturer for High Efficiency
With a 5,500 m² factory and a dedicated team of over 100 R&D and office personnel, Sedpharma delivers high-quality pharmaceutical equipment solutions worldwide.
Website:sedpharma.com
Key Products: Blister packaging machines for pharmaceuticals, customizable blister packaging solutions for tablets and capsules, medical device blister packaging equipment.
Key Services: Full service blister packaging line supplier, technical service for blister packaging needs of the pharmaceutical market.
Founded in 2012, SED Pharma focuses on blister packaging machinery specifically for pharmaceutical applications. Their machines, like the SED-GP Series, support high-speed blister packaging for ALU-PVC and ALU-ALU materials, with production speeds reaching up to 14,400 plates per hour. Designed for products like tablets and capsules, SED Pharma’s equipment meets industry standards for dosing precision and contamination control. With ISO9001 and CE certifications, and a focus on meeting FDA regulatory requirements, SED Pharma is a reliable choice for quality blister packaging solutions in the pharmaceutical sector.
2. Pharmaworks
Key Products: Semi-automatic blister packaging machines, high-speed blister machines, and compatible tooling for various OEM machines.
Key Services: Custom tooling design, technical consulting, and after-sales support, including training and maintenance.
Pharmaworks is a North American company that is a leading manufacturer of pharmaceutical blister machines. They offer a wide choice of blister packaging equipment: from semi-automatic machines for small-scale production to high-speed ones with the production rate of up to 300 blisters per minute. Pharmaworks also specializes in tooling that is compatible with different OEM machines and this makes them flexible to their clients.
3. Romaco
Key Products: Noack blister packaging machines, Unity series blister machines for various production capacities.
Key Services: Customized packaging solutions, rapid retooling support, technical support, and process optimization.
Noack of Romaco has become an internationally recognized supplier of durable and versatile blister packaging especially for small to medium runs. Their machines are valued for short cycle time retooling, high dependability and compactness and therefore are ideal for contract packaging firms and generics producers. Romaco has various types of blister machines, which are the Unity series, which are designed to meet various production requirements.
Conclusion
Blister packaging machines are useful for industries that need high security and anti-opening packaging options. In the production of pharmaceuticals, electronics among other products, these machines provide protective and aesthetic packaging solutions that improve product safety and attractiveness. While selecting a blister packaging machine, it is crucial to understand the needs of your products, the amount of money you are willing to spend, and the overall production capacity you want to achieve. Blister packaging machines are an investment in the product, its safety and quality, and customers’ satisfaction – all of which are critical in a competitive environment.
Leading Pharmaceutical Equipment Manufacturer for High Efficiency
With a 5,500 m² factory and a dedicated team of over 100 R&D and office personnel, Sedpharma delivers high-quality pharmaceutical equipment solutions worldwide.
If you are seeking for a reliable supplier of blister packaging, SED Pharma provides you with high quality and high speed packaging solutions for pharmaceutical market. With a special emphasis on accuracy, safety, and adherence to the rules. ISO9001 and CE certified, SED Pharma offers reliable equipment and professional service for the pharmaceutical industry. Go to sedpharma.com to find out how SED Pharma can assist you in improving your blister packaging process.
