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A blister pack is any of several types of pre-formed plastic packaging used for small consumer goods, foods, and for pharmaceuticals.
The primary component of a blister pack is a cavity or pocket made from a formable web, usually a thermoformed plastic. This usually has a backing of paperboard or a lidding seal of aluminum foil or plastic. A blister that folds onto itself is often called a clamshell.
Blister packs are useful for protecting products against external factors, such as humidity and contamination for extended periods of time. Opaque blisters also protect light-sensitive products against UV rays.
Blister packs are used to package products such as toys, hardware, medication, etc. Many blister packaging machines use heat and pressure via a die to form the cavity or pocket from a roll or sheet of plastic. In recent years, improvements in cold forming—specifically allowing steeper depth/angles during forming, which minimizes the amount of material used for each cavity—have helped this technology increase. The main advantages of the plastic-based blister pack are its more compact size compared to cold formed aluminum and its transparency to see the product.
Blister packs are commonly used as unit-dose packaging for pharmaceutical tablets, capsules or lozenges. Blister packs can provide barrier protection for shelf life requirements, and a degree of tamper resistance. In the US, blister packs are mainly used for packing physician samples of drug products or for over-the-counter (OTC) products in the pharmacy. In other parts of the world, blister packs are the main packaging type since pharmacy dispensing and re-packaging are not common. A series of blister cavities is sometimes called a blister card or blister strip as well as blister pack. The difference between a strip pack and blister pack is that a strip pack does not have thermo-formed or cold formed cavities; the strip pack is formed around the tablet at a time when it is dropped to the sealing area between sealing moulds. In some parts of the world the pharmaceutical blister pack is known as a push-through pack (PTP), an accurate description of two key properties (i) the lidding foil is brittle, making it possible to press the product out while breaking the lidding foil and (ii) a semi-rigid formed cavity being sufficiently collapsible to be able to dispense the tablet or capsule by means of pressing it out with the thumb. Breaking the lidding foil with a fingernail for the appropriate tablet will make the pressing out easier.
The main advantages of unit-dose blister packs over other methods of packing pharmaceutical products are the assurance of product/packaging integrity (including shelf-life) of each individual dose and the ability to create a compliance pack or calendar pack by printing the days of the week above each dose.
Blister packs are created by means of a form-fill-seal process at the pharmaceutical company or designated contract packer. A form-fill-seal process means that the blister pack is created from rolls of flat sheet or film, filled with the pharmaceutical product and closed (sealed) on the same equipment. Such equipment is called a blisterline. There are two types of blister machine' design: rotary and flat-plate, depending on the mechanism for sealing the lidding foil.
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