Vacuum Formed Plastics banner

Blister Packs

A reliable source for Blister Packs information and leading Blister Packs Companies & Suppliers.

Blister packs are preformed, clear plastic cavities formed through thermoforming. They are used for packaging small items such as food or pharmaceutical equipment. Blister refers to the pocket or cavity formed by thermoforming to cover the product. Read More…

Blister Packs Blister packs encompass a broad grouping of pre-formed thermoplastic packaging consisting of semi-rigid plastic shells. These forms may consist of two plastic sides sealed together, as with clamshells, or may be backed with cardboard or foil as needed to best suit a given application. Though mainly used in packaging, the design of blister packs makes them popular in a number of manufacturing and retail industries.
Request For Quote

Leading Manufacturers

Greeneville, TN  |  423-638-1284

Valk’s policy is “to meet or exceed our customer’s requirements, working together as a team with honesty and integrity.” Valk’s success is due to their long standing focus on quality & customer service.

Request A Quote

Valk Industries, Inc. $$$

New Milford, CT  |  860-354-0885

For over 40 years, Conlet Plastics has been a leader in vacuum forming. They serve a wide variety of industries including medical, airline, automotive and signage, with high-quality products that are reasonably priced & delivered on time.

Request A Quote

Conlet Plastics, Inc. $$$

Lake Bluff, IL  |  847-604-5100

Since 1960, Profile Plastics Inc. has been at the forefront of thermoforming technology. Utilizing the latest software and technology, our expert staff of engineers can design custom vacuum, pressure, and twin-sheet thermoformed solutions. Over the last 60 years, we have developed a process that allows us to deliver consistent, high volume, and precise products with superior quality. Our high quality products are manufactured with great attention to detail. ISO 9001:2008 certified.

Request A Quote

Profile Plastics, Inc. $$$

Stirling, NJ  |  908-647-3500

Engineered Plastic Products custom forms & fabricates sheet thermoplastic materials, standard & specialized, for any number of industrial & commercial requirements. EPP has been widely recognized for outstanding manufacturing & service since 1958 for companies such as GE, NASA & AT&T. Custom fabricated parts can be as large as 72"x108" down to 2"x2" in any thickness up to 1 1/2". Post-forming includes all types of machining & assembly.

Request A Quote

Engineered Plastic Products, Inc. $$$

McSherrystown, PA  |  717-633-6333

Founded in 1986, SAY Plastics is a plastics processor specializing in OEM thermoforming. Our state-of the-art facility, located in South Central Pennsylvania, houses the latest manufacturing technologies. From our computer controlled forming equipment and our vacuum molding capabilities, to our brand new high speed CNC Routers, SAY Plastics has the tools for your next project. Our team will work with you every step of the way to ensure quality service every time.

Request A Quote

SAY Plastics, Inc. $$$

Danville, IL  |  (844)865-1669

Greenwood Plastics Industries is an industry leader has been a leader in vacuum formed plastics for many years. We believe in relationships that can produce smart productivity. You give us the idea, and we will help you choose the best materials, process and timeline to make a high quality and profitable product. We are also committed to earth friendly-green solutions. Recycling as much as possible has been a company initiative for year and we are taking big steps at reducing our carbon footprint.

Request A Quote

Greenwood Plastics, Inc. $$$

Coleman, MI  |  877-465-4055

Robinson Industries offers thermoformed and injection molded reusable, heavy duty plastic pallets, packaging and more. We are one of the largest suppliers of reusable pallets to many industries.

Request A Quote

Robinson Industries $$$
placeholder image Valk Industries, Inc. Conlet Plastics, Inc. Profile Plastics, Inc. Engineered Plastic Products, Inc. SAY Plastics, Inc. Greenwood Plastics, Inc. Robinson Industries

Blister packs are preformed, clear plastic cavities formed through thermoforming. They are used for packaging small items such as food or pharmaceutical equipment. Blister refers to the pocket or cavity formed by thermoforming to cover the product. The backing is often a paperboard card or aluminum foil on which the product description is given. Blister packs are useful because they protect the product from temperature, humidity, and UV radiation.

Blister Packs

Features of Blister Packs

  • Blister packs are cost-effective. There are many different types with different prices.
  • There is advertising space on these packs, making it easier to learn about the product.
  • The product is visible and can be seen and checked before buying.
  • Blister packaging is heat-sealed; therefore, the packs are durable and secure. No one can duplicate the product or tamper with it.

Blister Packaging Process

PVC is used to make blister packs and is sealed by aluminum foil. The complete process is given below:

  1. Forming

    The process of thermoforming is what forms the clear plastic cavities. Thermoforming, in addition to cold forming, are the two types of forming processes. In cold-forming, the material is heated at room temperature and then stamped in the mold. Thermoforming is done by heating the material at a high temperature and then placing it in the mold.

  2. Product Loading

    After forming, the product is loaded into the clear cavities. Products can vary in shape and size.

  3. Sealing

    The next step is the sealing of the blister packs. The base and sealing material are joined together by applying pressure and temperature.

  4. Coding

    Coding is the next step. In this step, information such as batch number, expiry date, and manufacturing date is written on the blister packs to ensure convenience for the buyers.

  5. Perforation

    Perforation is the process of making minor cuts or holes in the plastic or paper packaging for easy removal of a part.

  6. Cutting

    The last process in blister packaging is the cutting of this packaging. Finally, a visual inspection is done to check for any broken tablet or seal. The process uses manual inspection systems along with blister positioning and rejection systems.

Types of Blister Packs

Many different types of blister packaging are on the market, each used for different purposes or client demands.

Face Seal Blister

  • The face seal blister pack is the most inexpensive and commonly used.
  • It consists of a flanged blister around the product, and the rest of the card remains uncovered.
  • This blister pack has a piece of heat-sealed paperboard on the back.
Face Seal Blister

Full Face Seal Blister

  • This blister pack covers the full face of the card, meaning there is no uncovered space on the card.
  • This packaging offers excellent strength and durability to the card and resists corner bending.
  • This packaging has more aesthetic appeal to buyers, although it is more expensive.

Trapped Blister

  • A trapped blister pack is the same as those mentioned above, but heat sealing is not required in these blisters.
  • The product is entrapped between two cards. The upper card is die-cut to fit the product.
  • As heat sealing is unnecessary, expensive heating tools are not required for this blister pack.
  • The backside of the card has an opening to access the product easily.
Trapped Blister

Full Card Blister

  • In this type, the whale flange is wrapped around the card placed on the back of the blister pack.
  • The card is put into the packaging and stapled in place.


  • A clamshell blister resembles a clam with two halves joined together to open and close.
  • It has robust, strong packaging and is used to pack heavy products.
  • These blisters also include a hole for hanging the product.
  • This packaging includes feet, which help it remain upright in the aisle.
  • Radiofrequency, heating, or UV radiations are used for sealing this pack; therefore, they are tamper-resistant.
  • Due to various sealing techniques and the expensive tools required, this packaging is costly.

Mock Clamshell

  • A mock clamshell is a one-piece blister with a card placed on the backside of the pack.
  • A lip extends backward to protect the edges of the card; this is also where graphics are incorporated.
  • It also helps in protecting the product from rough handling.
  • These are half the price of regular clamshells.

2- piece Clamshell

  • The 2-piece clamshell is a hybrid version of a mock clamshell.
  • A flat plastic packaging is glued onto the back of the blister pack.

Tri-fold Clamshell

  • The tri-fold clamshell is used for heavy and unstable products.
  • These blister packs have a hinged clamshell placed at the bottom of the packing.
  • When opened, these hinges turn into a triangular shape that helps protect unstable products from falling.
  • The tri-fold clamshell is the most expensive type of blister packaging.
Tri-Fold Clamshell

Applications of Blister Packs

Blister packs are used widely in many industries for packing products such as food, medical equipment, consumer goods, automobile and machinery parts, toys, accessories, beauty products, electronics, medicine, and many more.

Applications of Blister Packs

Blister Packs Informational Video


Plastic Molding Processes

Featured Industries