Plastic Blister

Plastic Blister – The Ultimate Guide

Plastic blister is an important and popular packaging solution in the pharmaceutical, food processing, chemical, and consumer electronics industries, amongst others.

As you can see below, a plastic blister is a preformed plastic material with a lidding seal made from plastic, paperboard or aluminum.

And, if you’re new to plastic blister for packaging, probably, you could be having many questions about this product.

The good news – you’ll get all the answers you have about blister pack here.

Advantages of Blister Packaging

Obviously, the use of blister packaging offers a wide range of benefits to both the company and the consumer.

Among these advantages include:

· Cost Reduction

Blister packaging reduces the packaging cost while increasing the packaging speed of your products as opposed to other forms of packaging

· Product Integrity

There is integrity maintenance of the product through rough Blister packaging. This is because of the shielding effect of the product by the package from adverse conditions.

You have an assurance that there will be no contamination of your product as a result of interaction with various factors. Such factors include air and moisture

· Ease of Identification

Blister packaging helps in easy identification of the dosage by its name, expiration date, and lot number. This way, customers can see the products they are purchasing.

· Product Customization

Blister packaging offers a manufacturing company the opportunity to customize their packages. Product personalization helps in having a unique, appealing product to your customers.

· Security

Blister packaging protects your product by ensuring it remains in a fixed position constant transit period. This helps in minimizing damages caused to the product such as breakage.

Material for Blister Packaging

There are different materials available for blister packaging. However, the product to be packed dictates the material for the blister packaging.

Plastic, in particularly thermoformed plastic, is the standard material for blister packaging. Thermoformed plastic includes the following types:

i. Poly Vinyl Chloride (PVC)

PVC is a low-cost plastic material that various manufacturers use in thermoforming due to its web forming characteristics. However, it is not ideal due to its ability to permit oxygen and water.

Another limitation of this material is that it is not environmentally friendly due to its chlorine levels. PVC is also known as Rigid PVC (RPVC) due to the lack of a plasticizer when using it for Blister packaging.

To overcome the oxygen and water porosity as well as the protective characteristic, coating of the PVC with other materials such as PVDC, PCTFE or COC is common.

The absence of a plasticizer makes the Blisters structurally rigid.  Also, there is a need for the blister packaging under this material to be accessible via push-through effect.

The formed web in this process needs to be easy to collapse upon the application of pressure. In pharmaceutical blister packaging, the use of multi-layer blister PVC films is common.

Here the PVC acts like the thermoformable backbone for the structure. Different colours can be applied on the PVC depending on the requirements.

The thickness of PVC material in blister packaging is usually between 250µ or 0.250 mm thick.

ii. Poly-chlor-tri-fluoroethylene (PCTFE)

Laminating this material with a PVC forms a high-quality material which is moisture proof depending on the structural level.

The structural level can be a duplex structure called PVC/PCTFE or a triplex structural level.

The structural level can be a duplex structure called PVC/PCTFE or a triplex structure called PVC/PE/PCTFE.  However, using a triplex structure and PE results in the formation of deeper cavities.

i. Polyvinylidene Chloride (PVDC)

PVDC when coated with PVC forms a packaging that is moisture and oxygen proof depending on the coating weight.

Coated PVDC is common in the formation of pharmaceutical blister packs. PVDC exist in either a triplex or duplex structure.

Also, you will find historic and super barrier grades of PVDC.

ii. Polyethylene Terephthalate (PETE)

Manufacturing clear plastic box packaging using this material results in durable transparent plastic packaging that is ideal for several applications. these includes packing of food products, beverages.

Using PETE as a material for blister packaging offers several benefits. These benefits include transparency, light weight and bottle neck precise molding.

iii. COC

This type of polymer material forms a perfect moisture barrier when you combine it with other polymers such as polypropylene and polyethylene.

Unlike other polymers, COC does not contain halogens or chlorine in its molecular structure.

iv. Polyethylene Terephthalate Glycol (PETG)

PETG is formed through copolymerization of ethylene glycol and PET. It is a watertight material making it an ideal material for the formation of blister packaging.

The advantage of this material is it allows for sterilization and recycling. Also, due to its high resistance, you can easily pack your products and transport them conveniently.

Difference between Strip and Blister Packaging

Depending on the needs of your customers, you can either have a strip or blister packaging. Even though they serve the same function, there is a slight difference.

Strip packaging refers to a form of packaging that involves enclosing the product between two web material. This way, each product is held between separate partitions.

However, it is not a must for the web of material to be similar.

On the other hand, there are two primary components of blister packaging. That is the cavity that is as a result of a formable material web and the sealing material that is mostly of aluminum, paperboard or plastic.

The cavity is the one that contains the product which is different from strip packaging where the holding of the product is between partitions.

When you compare to the production cost, strip packaging is relatively cheaper than blister packaging. Strip packaging machines are small and straightforward than the blister machines.

When you compare to space these packs occupy, strip blisters tend to occupy a lot of space than blister packaging.

Choosing Best Plastic Blister Packaging

Here are a few tips that will help you select the best plastic blister packaging to use.

· Barrier Properties

Apart from water penetration, plastic blister packaging needs to have barrier properties. Such properties include being air tight.

Also, adequate blister packaging should be waterproof, which ensures any form of liquid or moisture does not get in contact with your product.

By doing so, the product will remain fresh and safe for its intended purpose.

· UV Protection

By controlling the transparency of the plastic blister package, it can prevent penetration of UV light to the contents of the package.

The UV light can have an adverse effect on your product hence the need to ensure you select the best plastic blister package.

· Tamper-proof

The recycling of plastic blister packages is very ineffective due to the manufacturing process. By tampering with it, the likelihood of contamination of the product is relatively high.

Hence, for you to select the best plastic blister packaging, you need to ensure that it is tamper proof.

· Product Visibility

An effective plastic blister package is one that allows for the visibility of the product. Visibility will enable customers to make informed decisions about the product.

In medicines, visibility helps customers to check the tablets or capsules properly before purchasing.

· Good Chemical Resistance

There is a need to ensure that the plastic blister packaging has a high chemical resistance to prevent contamination of the product.

This ensures that it does not react with your product, which may lead to poisonous substances.

· Environmentally Friendly

For the safety of the environment, you need to ensure that the plastic blister packaging is safe to the environment. The use of recyclable material is highly encouraged.

· Allows for printability

An effective plastic blister packaging is one that allows for printability on its surface. Certain information needs to be printed on the surface the blister package to inform the customers.

However, such printing should not react with either the blister package or the product.

Types of Plastic Blister Packaging

You will find different types of plastic blister packaging in the market. The choice of which plastic blister packaging to use depends on the product you want to package.

The common types include:

i. Thermoformable Plastic Blister Packaging

These are the commonly used types of blisters in the market. You will find these blisters in the food packaging and medicine industries.

ii. Face Seal Plastic Blister Packs

Face seal plastic blister packs consist of a plastic film that has the product’s shape, which is heat sealed onto a paperboard. In case of a full -face seal, the plastic film runs from one edge of the package to the other.

iii. Trapped Plastic Blister Packaging

This involves the use of a single thermoformed film trapped within die-cut cardboard. Using this method does not require the use of any sealing tool.

iv. Full Card Plastic Blister Packaging

It consists of the plastic sheet covering all sides wrapping the paper lid.

v. Skin Plastic Blister Packaging

This type of plastic blister packaging involves the use of heat and vacuum, forming plastic blisters while using the products as molds.

Sandwiching of the product between the heated plastic sheets takes place followed by vacuuming.

vi. Stretch Card Plastic Blister Packaging

It is similar to skin packaging with the exception being the folding and attaching of the backing card to itself. This way, the product is covered by a transparent plastic sheet with a paperboard holding it.

Lastly, you have clamshell that utilizes hinged thermoformed plastic film. The use of this type of plastic blister packaging is common in the packaging of heavy products with the advantage of reusability.

Plastic Blister Packaging Machine Working Principle

There are three different plastic blister packaging machines available for use.

That is, thermoform, cold form plastic and thermo-cold complex plastic blister packaging machines

Let’s have a look at each of these plastic blister packaging machines to understand how they work.

In thermoform plastic blister machine, a plastic sheet unwinds from a reel flowing through a pre-heated station along the blister line. Here, due to the temperature, the plastic melts into a pliable state.

From here, the pliable plastic flows to the forming station where the application of pressure causes blister cavity formation. The next step involves cooling of the plastic, thereby making it rigid.

It maintains its shape after its removal from the mold. In cases of complex blister shapes, a plug assist helps in physically pushing the warm film down into the cavity.

This way, the blisters will have a uniform wall distribution. Such blisters are ideal if the cavity shape and size are large as compared to a small tablet.

The advantage of a thermoform plastic blister packaging machine include its transparency that allows you to view the product.  However, the use of PVC as the material is not suitable since PVC is a poor barrier to oxygen and moisture.

Also, this machine is not suitable for the packaging of light-sensitive products like certain drugs.

The use of a cold-forming plastic blister packaging machine is simple. This machine involves the use of an aluminum-based laminate sheet that is pressed to form a mold by using a stamp.

After that, the aluminum is elongated while maintaining the shaped formed. The resulting blisters are also known as cold-form foil (CFF) blisters.

The primary advantage of using this machine is that the aluminum offers a barrier proof for your product against water and oxygen. This has the effect of extending the expiry date for your product.

However, when you compare to the thermoform plastic blister machine, this machine is relatively slow. Also, the aluminum package lacks transparency.

The last machine is the thermo-cold plastic blister packaging machine. In this machine, there is the heating of the plastic, which is followed by thermoforming resulting in the formation of blister cavities.

After that, the packaging of the product takes place, which is followed by cold forming. This forms the required blisters after which sealing takes place.

Plastic Blister Packaging Process

Once the formation of the blisters is complete regardless of the machine used, the next step involves the packaging of the product.

Let’s examine how each machine handles the packaging process.

In thermoform plastic blister machine, once the blisters cool, the next step involves loading of the product. In this stage, filling the product into the blister cavity takes place either mechanically or manually.

There is the frequent application of vacuum extraction on the bowl tubes to minimize the finishing up of the tablets and powder chips on the tray.

At this stage, proper filing of the formed blisters is crucial.

The next stage involves the sealing of the blisters. Here, a lid stock is used to seal the blister cavity through pressure and heat application. At this stage, you need to pay attention to the pressure and temperature.

When using a cold forming plastic blister machine, the process of packaging starts after cold forming that results in blister cavity formation. Here, loading of the product takes place, followed by placing a sealing element over the blister.

After that, the heat-sealing process takes place followed by cutting of the package into individual blisters.

The vital thing to note is that there are different types of cold forming processes such as stretch forming and double forming operations.

The last machine is the thermo-cold forming machine. Blister packaging using this machine starts after thermoforming of the film to blister cavities.

The next step involves loading of the product into the blister cavities, followed by placing a sealing material on the blister.

After that, there is heat-sealing of the blister followed by the installation of an aluminum foil. Cold-forming takes place after this to give the package an extra protection.

To finalize the process, there is cutting of the blister into individual blisters.

The sealing material is a crucial part of the blister sealing. When selecting the material, you need to pay attention to its size, shape, style of the blister package and the product’s weight.

Also, you need to ensure that the surface of the sealing material is compatible with the coating process of the heat-seal. Additionally, check if the sealing material allows for printability.

The primary material commonly used is aluminum. A good heat-seal coating is one that has characteristics like clarity, hot tack, good gloss, and sealing in different blister films.

If you are to print on your sealant, you need to ensure the ink is resistant to the heat-seal temperatures and must resist abrasion.

Finding Plastic Blister Packaging Manufacturer in China

Finding a plastic blister packaging manufacturer in China, especially for first-timers, can be challenging given the long list of manufacturers.

However, this should not be a concern anymore. Here are tips that will be of help when looking for your manufacturer.

· Referrals

Referrals can be of help if you have friends in the industry who have previously done business with plastic blister manufacturers in China. Most people tend to refer others to the clients who offered satisfactory services to them.

· Trade Fair

Through attending various Chinese trade fairs, you are likely to interact with various plastic blister manufacturers in China and select your preferred.

Trade fairs are events held by the Chinese government that allows manufacturers to showcase their products.

An example of a trade fair in China is the Canton trade fair.

· Directories

Another key source of getting manufacturers is by searching on the directories. Directories contain a list of different plastic blister manufacturers with base in China and their address.

Through contacting these manufacturers, you can select one that you can engage business with depending on the negotiations you have with them.

· Online Platforms

Check out several legit inline platforms that allow for interaction between manufacturers and customers.

You will be able to interact with potential manufacturers before deciding on one to do business with. Remember, there are many plastic blister manufacturers on these online platforms.

However, to avoid inconvenience, check on the customer ratings of the different manufacturers. A manufacturer with the highest ratings is the ideal manufacturer for doing business with.

Even though these tips are helpful, there are a few considerations that you need to have in mind before you start doing business with your manufacturer.

For starters, check to make it a priority to visit the manufacturing plants. To avoid being duped, it is crucial to visit the physical plants of your plastic blister manufacturer.

Such visits ensure that you know the physical location of the plant and the address. Another consideration is that you need to ask questions for clarification purposes.

For instance, the production capacity, if they are willing to negotiate the prices and customization of your plastic blisters. More importantly, they should be in a position to deliver as per your schedule to avoid inconvenience.

Checking on their blister samples before deciding if they qualify for the job is also an important factor. This ensures that they meet your specifications, such as quality.

Plastic Blister Packaging Applications

There is a wide range of applications for plastic blister packaging. You will find this packaging in industries such as:

The pharmaceutical industry uses plastic blister packaging to package certain drugs depending on the required conditions. The advantage of using plastic blisters in this industry is you can preserve the drug in perfect condition.

For instance, plastic blister packaging prevents moisture and air from reaching the drugs, thereby contaminating it.

You expect to find plastic blister packaging in the food industry. Here, this packaging helps in preserving food, which ensures we get fresh food.

Also, plastic blister packaging helps us in viewing the product prior to purchasing or even consuming it. Some food manufacturers use this as an advertisement tool by making the product appealing to the customers.

Another application of plastic blister packaging is in the electronics industry. The use of plastic blister, in this case, is for packaging certain electronics conveniently.

Also, through the use of plastic blister packaging, these electronics are shielded from environmental hazard like breaking.

Sports is yet another industry that utilizes plastic, blister packaging. Specific sporting equipment such as tennis balls, golf balls, and helmets are packaged properly using plastic blister packages.

Another common application of plastic blister packaging is in office supplies, equipment, and stationeries. You will find plastic blister packaging in several office supplies like scissors and marker pens.

Lastly, kid’s toys are yet another common application of plastic blister packaging. Several kids’ toys are packaged using plastic blisters to make them secure as well as attractive for kids to purchase.

Conclusion

By now, you are an expert in plastic blisters. Of noteworthy is to note the different plastic blister forming machines as well as the different plastic blister packs.

Also, note that different applications utilize plastic blister, and these blisters differ depending on the application. It is therefore vital to select the appropriate plastic blister for your use.

If you still have any issue regarding plastic blister that you want us to clarify, feel free to get in touch with us today.