Core Materials: Blister Shells and Base Cards
(1) Blister Shell Materials
PVC (Polyvinyl Chloride)
Features: High transparency, flexibility, and low cost; easy to heat seal. However, it contains chlorine, posing environmental concerns.
Applications: Toys, daily necessities, small hardware tools (subject to environmental restrictions in regions like the EU).
PET (Polyethylene Terephthalate)
Features: Excellent transparency, strong temperature resistance (-40℃~60℃), non-toxic, eco-friendly, recyclable, and harder than PVC.
Applications: Food-contact products (e.g., candies, baking tools), cosmetics, electronics (compliant with FDA, LFGB, etc.).
PETG (Modified PET)
Features: Combines PET's environmental benefits with PVC's ease of molding; offers high impact resistance, ideal for complex blister shapes.
Applications: High-end gifts, medical devices, precision parts packaging.
PP (Polypropylene)
Features: Low density, good chemical resistance, high heat resistance (up to 120℃), but lower transparency.
Applications: Kitchenware, automotive parts, products requiring low-temperature transportation.
(2) Base Card Materials
White Cardboard/Coated Paper
Common grammages range from 250 - 400gsm. With a smooth surface, it suits color printing, often used for general daily product packaging (e.g., toothbrushes, razors).
Greyboard/Kraft Paper
Higher grammages (300 - 600gsm) provide strong rigidity, suitable for heavy products (e.g., tools, small appliances). Can be combined with corrugated paper for enhanced compression resistance.
Specialty Papers
Such as matte art paper (matte finish), metallic paper (luxury look), or recycled paper (aligns with ESG principles).
3. Classification and Typical Applications
(1) Structural Types
Insertion Blister Cards
The blister and card are secured via slots, eliminating the need for heat sealing. Easy to open and close, they are ideal for products requiring repeated access, like stationery or small toys.
Heat-Sealed Blister Cards
The blister's edges are bonded to the card through high-temperature pressing, ensuring a secure seal to prevent product displacement. Commonly used for electronics (earphones, chargers) and beauty tools.
Folding Blister Cards
The card folds with blisters heat-sealed on both sides, offering dual-sided display. Suitable for multi-product sets, such as cosmetic kits or tool assortments.
(2) Application Areas
Daily Necessities: Toothbrushes, razors, combs (the transparent blister highlights product design, while the card prints ingredients and usage instructions).
Electronics: USB drives, earphones, smartwatches (blisters protect against shocks and scratches; cards integrate anti-counterfeiting codes and product specifications).
Toys/Models: Building blocks, action figures (blisters fix product positions; cards feature IP designs or background stories to enhance collectability).
Food/Pharmaceuticals: Baking tools, disposable cutlery (PET material meets food safety standards; cards display compliance certifications).
4. Key Advantages of Blister Cards
Visual Marketing: Transparent blisters showcase products directly, reducing consumer decision-making time and boosting purchase intent.
Protection: Blisters cushion impacts, and the card structure provides additional support, suitable for long-distance shipping and shelf display.
Cost-Effective: Compared to gift boxes, blister cards are cheaper in materials and production, enabling mass automated manufacturing.
Design Flexibility: Blisters can be customized into unique shapes (e.g., curves, 3D bulges), while cards support advanced printing techniques like foil stamping, UV coating, and embossing for brand differentiation.
5. Design and Production Considerations
(1) Design Essentials
Size Compatibility
Blister depth should allow 1 - 2mm clearance for the product to prevent damage. Card dimensions must align precisely with blister edges (heat-seal margins typically 5 - 10mm).
Printing Processes
Confirm the card's ink absorption properties before printing (coated paper suits CMYK printing; kraft paper may require spot colors). Ensure clear areas for barcodes and anti-counterfeiting marks to avoid color discrepancies.
Regulatory Compliance
For exports, verify material compliance with target markets (e.g., RoHS in EU, ASTM F963 in US). Prioritize recyclable materials like PET and PP.
(2) Production Process
Thermoforming
Heat plastic sheets until malleable, then vacuum - form them into molds. Control temperature (PVC: 140 - 160℃; PET: 180 - 200℃) and cooling time to prevent uneven thickness.
Cutting and Heat Sealing
Bond blisters to cards using heat sealers with consistent pressure (usually 5 - 8kg/cm²) to avoid edge curling or piercing.
Quality Control
Inspect key aspects: blister clarity (free of impurities and bubbles), heat-seal strength (peel test), and dimensional accuracy (tolerance ≤±0.5mm).
6. Common Issues and Solutions
| Problem | Cause | Solution |
|---|---|---|
| Bubbles in blisters | Uneven heating or blocked mold vents | Calibrate temperature controls; clean mold vents |
| Poor heat - seal adhesion | Insufficient heat or incompatible card coating | Increase heat - seal temperature by 5℃; use specialized heat - seal coated cards |
| Blister deformation | Short cooling time or high storage temperature | Extend cooling duration; store in shaded areas |
| Printing color deviation | Ink batch variations or paper moisture fluctuations | Conduct pre-production samples; maintain paper humidity at 55% - 65%RH |
7. Future Trends: Sustainability and Innovation
Biodegradable Materials
Bio-based PET (e.g., corn starch - derived) and compostable PP are replacing traditional plastics, meeting global decarbonization goals.
Digital Printing Advancements
Variable Data Printing (VDP) enables personalized packaging, while QR codes integrate with product websites or AR experiences, enhancing user engagement.
Lightweight Design
Optimized structures (e.g., thin - walled blisters, perforated cards) reduce material usage without sacrificing protection.
Conclusion
Blister cards serve as a practical yet impactful packaging solution across various industries. From material selection to production, each step requires a balance of functionality, cost, and environmental considerations. As the packaging industry evolves towards sustainability and intelligence, blister cards will continue to innovate, adding greater value to products. Whether you're a brand owner or a consumer, understanding blister card fundamentals can optimize their role in product distribution.
contact us
WhatsApp：(+86)18933510649
email：02@sognhongpaper.com
website：https://www.grayboardpaper.com/
address：(Factory Building) Hengyu Road 4th, Sandong Digital Park, Huicheng District, Huizhou City, Guangdong Province
YouTube：https://www.youtube.com/@songhongpaper-02