Custom Blister Packaging


custom blister packaging for turned edge pads, binders, and press kits


Blister Packaging

What is Custom Blister Packaging?

Thermoform blister packaging is a trusted retail ready packaging solution. Originally patented in 1947 for the purpose of storing aspirin tablets, the production of blister packaging has evolved somewhat over time. However, its duty at retail has grown invaluable.

Custom blister packaging begins with a grade of plastic heated and molded to fit a product on a sturding backing. This process creates a tailor-fit plastic cavity which secures the product in clear casing, preventing movement and damage. Fortunately, this protective bubble around the product proves as much a marketing strategy as a security measure.

 

How Does it Work?

The vacuum formed casing heat-sealed to the cardback deters tampering. It’s easily recognizable when blister packaging is disturbed. At the same time,the transparency of the blister pack allows the product to be on display, rather than just an image. Seeing the product is better than any high-resolution image. It means a potential buyer can be that much closer to the product without it being loose. Much of retail tampering is not theft-related, but caused by a frustrated consumer just wanting a better look at the product, to see if it works for their needs. Clear blister packaging provides that advantage.

 

Blister Packaging

Benefits of Blister Packs

Blister packaging is a staple of retail for lightweight, high-volume products. Easy to ship, easy to stock, easy to open. Available styles include face seal, trap mock, and slide, with a variety of backing materials such as SBS paperboard, E-flute corrugated cardboard, and foil for truly customized and attractive packaging. The addition of cardboard or paperboard gives blister packaging extra room for descriptions and logos, while providing high-quality color printing.

 

Sunrise Packaging’s unique facility can manufacture not only standard blister packaging, but also customized blister packs for binders, pads, and kits. Contact one of our packaging experts for more details to see how blister packaging can create a more memorable presentation for your project.

 

Plastic Blister Packaging Advantages

  • Practical and Affordable
  • Clear Product Display
  • Theft Deterrent
  • Tamper Evident
  • Product Protection

Blisters vs. Clamshells

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Popular packaging solutions such as clamshells and blisters are the product of thermoforming. You see them all around you in retail stores. Many think that clamshells and blisters are the same thing but they’re different. Lets investigate:Clamshells:

Most commonly used in retail products. Clamshells have hinges that allows them to open like a clamshell. A clamshell package with a single hinge usually includes a hanger tab so it can be hung on a store peg. Some clamshells have multiple hinges which gives them a flat base and allows them to be stood upright on a shelf. Retail products can be showcased very well in clamshell packaging. The clarity and visibility allows consumers to get a full view of the product. Clamshells can also be customized and thermoformed to take on any shape and hold a multitude of products.

Blisters:

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Blister packaging is also commonly used in retail packaging specifically for small consumer goods, food, and pharmaceuticals. The main difference between a blister and a clamshell is that a blister doesn’t have a hinge. It it still made from thermoformed plastic. Blisters, in a lot of applications, are attached to a paperboard card where the blister mold holds the product in place. Blisters are also great for showcasing products because their clarity leads to great visibility.

Blister Packs and Clamshells Everywhere!

 

Start Seeing Blister Packs

When you go into just about any department store or pharmacy, you can often find a wall or two–and an aisle or three–that are covered wall-to-wall in product merchandise. Product, product everywhere, encased in individual blister packs or plastic clamshells. Why? For starters, blister packs are a simple solution to both protecting and displaying retail merchandise. A retail ready solution that has withstood the test of time.


Theft-Deterrent and Marketing Strategy in One

thermoformed plastic blister packs for electronics retailThe most common types of packaging are made of thermoformed thin-gauge plastic. This particular gauge is used for packaging cosmetics, electronics, as well as items vital to the pharmaceutical industry. The main benefits of this packaging category prove the value of blister backs. Thermoformed packaging is tamper-evident–and often tamper proof! This is a great deterrent of theft, and makes for a highly-noticeable attempt. The clear plastic packaging gives the consumer the opportunity to actually see the product in its entirety. A product a consumer can see is a product that they will believe. Finally, high volume markets–such as with electronics–require speedy manufacturing and fulfillment to keep up with consumer demand. Blister Packs and clamshells are a fairly standard design, decreasing the turnaround time on orders


 

A Time-Honored Process

With in-line thermoforming processes, packaging manufacturers are able to produce both blister pack cavities and full two-sided clamshells in an efficient and streamlined way. Roll-fed into the thermoformer, thin gauge plastic travels through an aluminum mold that, when applied with heat and a vacuum, will conform the material to that exact shape and size.

Thermoforming is an old process, only fairly changed since its inception, but it is a proven solution for churning out reliable, protective retail packaging.

Learn More about Blister Packaging

Thermformed Plastic Trays

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Custom thermoforming offers the manufacturer the ability to create a unique packaging solution for anything. That’s right- anything. While thermoformed blister packaging and custom clamshells are generally geared toward the electronic and cosmetic markets, thermoformed plastic trays are applicable to any packaging purpose. The plastic forming process is simple, quick, and economical for production runs large and small, and with custom aluminum tooling, products fit snug into their respective place. Here are some markets that currently use or could greatly benefit from their own custom thermoformed plastic trays:

mechanical/automotive: plastic trays can be formed to hold parts large and small alike. Great for mechanical maintenance or as a presentation for the buyer! Present  a kite with the car manual, title, keys, and throw in a tire gauge for the new car owner!

art/design: perfect tool hold any kind of utensil- keep paintbrushes, pencils, and other tools in a compact and accessible kit. Plastic trays are durable and washable for the messier artist as well…I mean, did Da Vinci worry about paint drips on the ground? I don’t think so.

jewelry/accessories: for an affordable set of jewelry or an organized accessory kit, a plastic tray is perfect for separating by color or style.

wine and spirits: limited edition liquors and wines are a great way to promote high-end alcoholic beverages, new and old. Plastic trays can hold bottles, bottle openers, martini shakers, and more in a comprehensive little kit that true patrons would love to take home!

electronics: in our growing global economy and interweb we’ve got gadgets and gizmos a plenty! Many come with small parts and extra accessories that are valuable to the end use of the product– which is most likely pretty spendy. Keep track of each component with custom plastic trays.

financial/banking: whether it is to hold currency, poker chips, or a banking welcome packet, thermoformed plastic trays can play an integral part in a marketing kit that adds value to the service you provide.

Can you think of any markets that wouldn’t benefit from using plastic trays? Try and stump me by emailing marys@sunpack.com, I’m up for a challenge!

 

 

Sports Electronics Packaging

We found this packaging example on the online gallery, Packaging of the World. Housing sports electronics products, these plastic thermoformed cases offer security and display qualities that are perfect for a retail environment. The challenge that the packaging designer was faced with was the need to refresh the brand to appeal to a younger audience. The designer used accent colors on the packaging in order to categorize products without confusing their targeted consumers. We love this creative use of plastic formed packaging- it does not stay constrained to a classic clamshell or blister pack. These are truly unique packaging solutions that will add value to the product and intrigue more consumers. sportline-potw-01

Why Thin Gauge Plastic?

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The majority of the thermoformed packaging solutions that you will see are made from a thin gauge plastic material. As an inline thermoforming manufacturing company, we believe that thin gauge plastic is one of your best bets when designing and producing custom plastic packaging products. Small sized blister packaging and clamshells from Sunrise can be made with a wide variety of different thing gauge plastics that offer different benefits suited to your needs. In retail and food industries, thin gauge plastic is the most common used material. This is because of its malleability and quick forming capabilities. Most often received in material rolls, thin gauge thermoplastic can simply be setup with the inline thermoformer and automated through the process. For fast moving items in the retail world, this is beneficial to both retailer and supplier!

Plastic Clamshell Solutions

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Plastic clamshells can be seen in a wide variety of retail stores. From large scale department stores to small mechanical or electronic outfits, clamshell packaging is applicable to so many products that are sold today. The main reason for the popularity of clamshells is the protection they offer product while giving the consumer the best possible idea of what they are about to purchase. What many consumers may not consider, however, is how economical and environmentally conscious it is of these companies to opt for plastic clamshell packaging. A thermoformed item, plastic clamshells most often use a clear, sometimes recycled and always recyclable PVC grade plastic. A thin and clear material that allows for efficient inline thermoforming manufacturing. Producing large quantities of plastic thermoformed trays, blisters, or clamshells is a fast process for most manufacturers after tooling and setup. Consider plastic packaging solutions like clamshells for your next retail venture. Even with startups or smaller quantities, stock clamshell sizes can be a viable option. Sunrise Packaging has a selection of seven new clamshells to choose from. Even order online!

Custom Plastic Packaging Factors

thermoformedWhen making packaging decisions for retail products, there are a lot of factors that come into play, and many important things to consider. Custom plastic thermoformed packaging comes as no exception. In order to have an all around quality packaging solution, it needs to be protective and practical while simultaneously marketing your brand and product. Protection and practicality go hand in had for custom packaging solutions. In order for  a plastic blister pack or clamshell to properly serve its purpose, it needs to insure that the product is safe in shipping, that it is tamper proof in-store and can therefore be purchased and put to use! Simplicity is also a key component of quality packaging. Many times with plastic clamshells and blisters, shoppers find it difficult to actually access the product that they just bought! Create a design that offers protection but can also be easily opened in the household- there are a few tricks out there to open difficult plastic packaging, many of which come with a bit of risk. Finally, use packaging to your advantage by adding value to your in-store presence. You worked hard on making the packaging design, now make it work for you. Incorporate your marketing message and branding strategies when you design artwork, tooling, and more!

Aluminum Tooling: Watch How it’s Made

custom toolingFor high quality custom thermoforming, the process starts with an aluminum tool that plastic is formed by. In order to accurately fit products into a custom clamshell, blister pack, or tray it is important that the tooling match the layout and dimensions of the set.

As a turnkey manufacturer, we offer in-house tooling services to keep production in extremely close proximity to the tooling department to ensure accuracy and close communication. Watch our youtube video below to watch how it’s made. We take all necessary action to make sure that the custom tool works properly in our inline thermoformer, and will produce a mock-up of the product to confirm accuracy and quality. To create an ideal package for retail products, cosmetics, and more, consider custom thin gauge thermoforming to create a tamper evident, eye-catching package that displays your product in a competitive retail environment.

Consumer Products: Blister Packaging

pocketmonkeyWhile we emphasize the security and display that is associated with custom thermoformed clamshell packaging, there are other plastic packaging solutions that can offer similar display benefits and tamper evidence in retail. Using branded artwork is much easier to do with blister packaging, because the concept of the item requires a blister card anyways– might as well print with eye-catching graphic design! The thermoformed cavity is then heat sealed onto each card holding the product in place. See here our example of our custom-made packaging for the Pocket Monkey product. When it comes to security, the blister pack keeps items protected from their external environment. However, since they are easier to open than clamshells, there is still a possibility of tampering. While this does not protect the product itself, it does protect the consumer, making any evidence of tampering obvious to the shopper. Plastic blister packaging are commonly used for pharmaceutical products, but are also extremely popular in general consumer goods packaging.