The Complete Guide to the Manufacturing Process of Blister Paper

For more than 20 years, we at Huizhou Songhong Industrial Co., Ltd. have dedicated ourselves to the innovation, production, and distribution of high-quality paper products. Among our portfolio, blister paper has emerged as a standout product due to its unique characteristics and wide application across numerous industries. In this article, we provide a comprehensive overview of the blister paper manufacturing process, from raw material selection to final product quality control. This guide is crafted with the latest SEO principles to help readers and industry professionals understand what makes blister paper a preferred packaging material.

What is Blister Paper?

Blister paper, often used in blister packaging, refers to a type of specialty coated paper or cardboard that serves as the backing in blister pack assemblies. It is typically used in pharmaceutical packaging, electronics, toys, cosmetics, and stationery.

🔵 Blister Paper Definition

Blister paper combines paperboard with a layer of heat-sealable coating, allowing it to adhere to a plastic blister through heat and pressure. This creates a tamper-evident, protective, and visually appealing packaging format. The coatings can vary depending on application-ranging from PE, PVC, PET, or foil laminates.

🔷 Key Applications of Blister Paper

Blister packaging is the most well-known application, providing secure sealing, excellent printability, and resistance to environmental factors. Some major uses include:

Pharmaceutical Blister Packs

Toy Packaging

Battery and Electronics Backing

Stationery Packaging

Hardware Product Cards

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🏭 Step-by-Step Manufacturing Process of Blister Paper

Below, we break down the production process of blister paper into detailed stages to help you understand the technical and quality aspects involved.

🔹 1. Raw Material Selection

The first and most crucial step is selecting the base paperboard material. Quality starts here.

✅ Common base paper grades:

Ivory board

Grey board

SBS (Solid Bleached Sulfate)

Duplex board with grey back

We use virgin wood pulp or recycled pulp, depending on the customer's requirements and environmental preferences. Pulping, cleaning, and screening are essential to ensure fiber consistency and cleanliness.

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🔹 2. Paperboard Formation

Once the pulp is refined, it undergoes the wet-end process, where the fibers are distributed evenly on a wire mesh screen to form a sheet. This sheet is then drained, pressed, and dried to achieve a consistent GSM (grams per square meter).

Typical GSM for blister paper ranges between 200g to 500g, depending on the application. Thicker boards are used for heavy-duty packaging.

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🔹 3. Surface Sizing and Coating

This is where the magic of blister sealing compatibility happens.

The dried board is fed into a coating machine, where it is treated with sealant resins such as:

PE (Polyethylene)

PVC-compatible coatings

PET-compatible coatings

Heat-sealable glue

The coating may be single-sided (C1S) or double-sided (C2S) depending on whether one or both sides require sealing or printing.

🌟 Functions of the coating:

Enables heat sealing to plastic

Improves moisture resistance

Enhances surface smoothness for offset printing

Increases durability

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🔹 4. Drying and Calendering

After coating, the paperboard is passed through high-temperature drying cylinders. Once dried, it undergoes calendering-a finishing process where the paper is passed between rollers to:

Smooth the surface

Improve gloss

Enhance printing characteristics

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🔹 5. Quality Inspection and Testing

Every batch of blister paper undergoes stringent quality control. We perform tests to verify:

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🔹 6. Slitting and Sheet Cutting

Depending on the final use, the blister paper is either:

Sheeted into standard sizes like 787×1092mm, 889×1194mm, or

Slit into rolls for automatic blister sealing machines

We offer custom sizing for high-speed form-fill-seal (FFS) operations or traditional manual sealing.

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🔹 7. Packaging and Delivery

The final blister paper sheets or rolls are packed using moisture-proof wrapping and edge protection materials to prevent transit damage. Palletization is optimized for both domestic delivery and export.

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🟠 Types of Blister Paper Coating Structures

We offer various coating structures depending on customer needs:

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💹 Development Trends in Blister Paper Manufacturing

The blister paper industry is rapidly evolving. Here are the main trends shaping its future:

🔸 1. Sustainability Focus

With rising environmental concerns, the industry is shifting toward:

Recyclable blister paper

Biodegradable coatings

FSC-certified raw materials

Plastic-free blister alternatives

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🔸 2. Digital Print Compatibility

Clients demand custom packaging and short-run printing. Our newer blister boards are engineered for compatibility with:

UV offset printing

Flexographic presses

Digital inkjet presses

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🔸 3. High-Speed Production Compatibility

Blister paper must perform under high-speed automated packaging machines without delamination or curl. We optimize for:

Low static

Stable curl control

Uniform coating adhesion

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🔸 4. Application Expansion

Beyond pharma and toys, blister paper is now expanding into:

Food-grade blister trays

Health supplement cards

Smart packaging with QR/NFC tags

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✅ Why Choose Us as Your Blister Paper Manufacturer?

With over 20 years of experience, we provide:

In-house coating and laminating lines

OEM/ODM services

Strict ISO-certified quality systems

Flexible MOQ and fast lead times

We currently export to Europe, North America, Southeast Asia, and South America, serving top brands in retail, pharma, and stationery sectors.

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📦 Conclusion

The manufacturing process of blister paper involves a complex integration of papermaking, coating, and quality testing to deliver a product that is printable, heat-sealable, and durable. As industries push for sustainability and precision in packaging, blister paper will continue to evolve in structure, performance, and ecological compliance.

Whether you need heat seal blister paper, PE coated blister board, or custom die-cut blister cards, we at Huizhou Songhong Industrial Co., Ltd. are ready to supply top-quality solutions tailored to your needs.

📈 Interested in working with us? Contact our sales team for free samples and technical sheets.