{"id":7760,"date":"2025-09-19T09:00:00","date_gmt":"2025-09-19T08:00:00","guid":{"rendered":"https:\/\/uplastech.com\/blister-packaging-design\/"},"modified":"2025-09-19T09:00:00","modified_gmt":"2025-09-19T08:00:00","slug":"blister-packaging-design","status":"publish","type":"post","link":"https:\/\/uplastech.com\/it\/blister-packaging-design\/","title":{"rendered":"Blister Packaging Design: Cavity, Card Seal and Retail Handling"},"content":{"rendered":"<style>\n.upl-blog{font-size:17px;line-height:1.78;color:#1f2937}\n.upl-blog p{margin:0 0 18px}\n.upl-blog h2{font-size:26px;line-height:1.3;color:#0b2b33;margin:46px 0 14px;font-weight:700;letter-spacing:-.015em}\n.upl-blog h3{font-size:19.5px;color:#0d3b47;margin:28px 0 10px;font-weight:700}\n.upl-blog ul,.upl-blog ol{margin:0 0 20px;padding-left:22px}\n.upl-blog li{margin:0 0 9px}\n.upl-blog figure{margin:0 0 34px}\n.upl-blog figure img{width:100%;height:auto;display:block;border-radius:10px}\n.upl-blog figcaption{font-size:13px;color:#6b7280;margin-top:10px;line-height:1.5}\n.upl-blog .toc{background:none;border:0;border-radius:0;padding:0;margin:0 0 34px}\n.upl-blog .toc .lwptoc{margin:0}\n.upl-blog .toc h4{margin:0 0 10px;font-size:13px;letter-spacing:.1em;text-transform:uppercase;color:#0d5563}\n.upl-blog .toc ol{margin:0;padding-left:18px;font-size:14.5px}\n.upl-blog .toc li{margin-bottom:6px}\n.upl-blog table{width:100%;border-collapse:collapse;font-size:14.5px;margin:0 0 10px}\n.upl-blog th{background:#0d3b47;color:#fff;text-align:left;padding:11px 13px;font-weight:600;font-size:13.5px;border:0}\n.upl-blog td{padding:11px 13px;border:0;border-bottom:1px solid #e8ebed;vertical-align:top}\n.upl-blog tbody tr:nth-child(even){background:#fafbfc}\n.upl-blog .tablecap{font-size:12.5px;color:#6b7280;margin:0 0 30px}\n.upl-blog .myth{background:#fff8ef;border:1px solid #f6ddbd;border-radius:8px;padding:16px 20px;margin:0 0 26px;font-size:15.5px}\n.upl-blog .myth b{color:#a85c10}\n.upl-blog .callout{background:#f2f8f9;border-radius:8px;padding:18px 22px;margin:0 0 26px;font-size:15.5px;border-left:3px solid #14707f}\n.upl-blog .faq h3{border-top:1px solid #eceff1;padding-top:22px;margin-top:0;font-size:18px}\n.upl-blog .faq h3:first-of-type{border-top:0;padding-top:0}\n.upl-blog .cta{background:linear-gradient(135deg,#0b2b33,#0d5563);color:#fff;border-radius:12px;padding:34px;margin:48px 0 30px}\n.upl-blog .cta h2,.upl-blog .cta .cta-h{color:#fff;margin:0 0 10px;font-size:24px;font-weight:700;line-height:1.3}\n.upl-blog .cta p{color:#c9dee3;margin:0 0 20px;font-size:16px}\n.upl-blog .btn{display:inline-block;background:#e07a1f;color:#fff;text-decoration:none;font-weight:700;padding:13px 26px;border-radius:8px;font-size:15.5px}\n.upl-blog .rel{border-top:1px solid #e8ebed;margin-top:40px;padding-top:26px}\n.upl-blog .rel h4{font-size:13px;letter-spacing:.1em;text-transform:uppercase;color:#6b7280;margin:0 0 14px}\n.upl-blog .rel ul{list-style:none;padding:0;margin:0}\n.upl-blog .rel li{padding:11px 0;border-bottom:1px dashed #e8ebed}\n.upl-blog .rel a{text-decoration:none;font-weight:600;font-size:15.5px}\n@media(max-width:640px){.upl-blog h2{font-size:22px}.upl-blog table{font-size:13px}.upl-blog .cta{padding:24px}}\n\/* \u5355\u7bc7\u9875\u9690\u85cf WhatsApp \u95ee\u5019\u5361\uff0c\u53ea\u4fdd\u7559\u5706\u5f62\u6c14\u6ce1\uff0c\u907f\u514d\u906e\u6321\u4fa7\u680f\u8be2\u76d8\u63d0\u4ea4\u6309\u94ae\u3002\n   \u6ce8\u610f\uff1aClick to Chat \u7684\u70b9\u51fb\u903b\u8f91\u662f\u300c\u95ee\u5019\u5361\u5143\u7d20\u5b58\u5728\u5c31\u4e0d\u8df3\u8f6c\u300d\uff0c\u53ea\u9760 CSS \u9690\u85cf\u4f1a\u8ba9\u6c14\u6ce1\u53d8\u6210\u6b7b\u94fe\u63a5\u3002\n   Code Snippets #9\u300cUPL single post: WhatsApp bubble jumps straight to chat\u300d\u8d1f\u8d23\u628a\u8be5\u8282\u70b9\u4ece DOM \u79fb\u9664\uff0c\n   \u4e0b\u9762\u8fd9\u6761 CSS \u53ea\u662f\u79fb\u9664\u524d\u7684\u89c6\u89c9\u515c\u5e95\u3002\u5220 #9 \u524d\u5fc5\u987b\u5148\u5220\u8fd9\u6761\u89c4\u5219\u3002 *\/\nbody.single-post .ht_ctc_chat_greetings_box{display:none !important}\n<\/style>\n<div class=\"upl-blog\">\n<figure>\n<img fetchpriority=\"high\" decoding=\"async\" src=\"https:\/\/uplastech.com\/wp-content\/uploads\/2026\/10\/blister-packaging-design.jpg\" alt=\"Clear PVC blister packs sealed to printed cards with hardware items inside\" width=\"1536\" height=\"909\"><figcaption>A blister pack is three products in one: a formed cavity, a printed card and a seal. The seal is the part that fails.<\/figcaption><\/figure>\n<div class=\"toc\"><\/div>\n<h2 id=\"job\">What a blister actually has to do<\/h2>\n<p>A blister pack does four jobs at once, and most design arguments come from two people optimising different ones.<\/p>\n<p>It has to <strong>hold<\/strong> the product so it cannot move, rotate or rattle. It has to <strong>show<\/strong> it, because the pack is the only advertising a product gets on a shelf. It has to <strong>protect<\/strong> it through a supply chain that includes a pallet drop. And it has to <strong>resist<\/strong> being opened and resealed, because a pack that can be opened in store is a theft problem.<\/p>\n<p>The cavity does the first two, the card does the third and fourth, and the seal decides whether any of it works. A pack that is designed beautifully and sealed badly arrives on the shelf with the product loose in the bottom of the carton.<\/p>\n<h2 id=\"material\">The three materials, and why PVC still dominates<\/h2>\n<p>Blister cavities are made from a small set of materials, and the choice is driven by the seal more than by anything else.<\/p>\n<table>\n<thead>\n<tr>\n<th>Materiale<\/th>\n<th>Spessore<\/th>\n<th>Clarity<\/th>\n<th>Seal to coated card<\/th>\n<th>Note<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>PVC<\/td>\n<td>0.3 \u2013 0.8 mm<\/td>\n<td>Eccellente<\/td>\n<td>Excellent, no coating needed<\/td>\n<td>The default for 50 years<\/td>\n<\/tr>\n<tr>\n<td>PETG<\/td>\n<td>0.3 \u2013 0.8 mm<\/td>\n<td>Eccellente<\/td>\n<td>Good with a coating<\/td>\n<td>The common PVC replacement<\/td>\n<\/tr>\n<tr>\n<td>APET<\/td>\n<td>0.3 \u2013 0.6 mm<\/td>\n<td>Eccellente<\/td>\n<td>Difficult, needs coating<\/td>\n<td>Stiffer, more brittle<\/td>\n<\/tr>\n<tr>\n<td>PS<\/td>\n<td>0.3 \u2013 0.8 mm<\/td>\n<td>Buono<\/td>\n<td>Buono<\/td>\n<td>Cheap, brittle<\/td>\n<\/tr>\n<tr>\n<td>PP<\/td>\n<td>0.3 \u2013 0.6 mm<\/td>\n<td>Fiera<\/td>\n<td>Poor \u2014 needs special coating<\/td>\n<td>Used where chemical resistance matters<\/td>\n<\/tr>\n<tr>\n<td>PCTFE \/ Aclar<\/td>\n<td>0.1 \u2013 0.3 mm<\/td>\n<td>Eccellente<\/td>\n<td>Via lamination<\/td>\n<td>High barrier, pharmaceutical<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 1 \u2014 Blister materials. PVC dominates because it heat-seals to a coated card without any surface treatment.<\/p>\n<p>The PVC dominance is not sentiment. PVC softens at a low enough temperature that the seal can be made without distorting the cavity, and it bonds to the solvent-based coating on the card by dissolving into it. That combination is difficult to reproduce with a polyolefin, which is why PP blisters need a special coating and still seal less reliably.<\/p>\n<p>The environmental pressure on PVC is real and it has moved a large share of the market to PETG, which is a copolyester that forms and seals almost as well and is mechanically recyclable. The cost is 15 to 30% higher and the seal needs a coating formulated for polyester rather than for PVC, which means the card supplier has to be told.<\/p>\n<div class=\"callout\">\n<p><strong>Tell the card printer which blister material you are using.<\/strong> The heat seal coating on the card is formulated for a specific polymer. A PVC-coated card will not seal to a PETG blister, and the failure looks like a temperature problem.<\/p>\n<\/div>\n<h2 id=\"cavity\">Cavity design: the product has to be held, not just covered<\/h2>\n<p>The most common blister design fault is a cavity that is a loose box around the product. The product rattles, rotates, and in transit it works its way to the edge and punctures the seal.<\/p>\n<p>A good cavity locates the product on at least three features and holds it against the card. That can be ribs that contact the product, a shaped pocket that matches its outline, or a small undercut that the product snaps behind.<\/p>\n<table>\n<thead>\n<tr>\n<th>Parametro<\/th>\n<th>Typical value<\/th>\n<th>Consequence<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Cavity depth<\/td>\n<td>Product height + 1 \u2013 2 mm<\/td>\n<td>Too shallow: product presses on the card. Too deep: it rattles<\/td>\n<\/tr>\n<tr>\n<td>Cavity width<\/td>\n<td>Product + 0.5 \u2013 1.5 mm per side<\/td>\n<td>Too tight: hard to load. Too loose: movement<\/td>\n<\/tr>\n<tr>\n<td>Draw ratio (depth \/ width)<\/td>\n<td>Up to 1.5 : 1<\/td>\n<td>Above 2 : 1 the walls thin and the corners crack<\/td>\n<\/tr>\n<tr>\n<td>Corner radius<\/td>\n<td>At least 1.5 \u00d7 wall<\/td>\n<td>Sharp corners are where cracks start<\/td>\n<\/tr>\n<tr>\n<td>Wall thickness<\/td>\n<td>0.3 \u2013 0.8 mm<\/td>\n<td>Below 0.3: too weak. Above 0.8: hard to form and seal<\/td>\n<\/tr>\n<tr>\n<td>Draft angle<\/td>\n<td>2 \u2013 5\u00b0<\/td>\n<td>Zero: the part drags and sticks<\/td>\n<\/tr>\n<tr>\n<td>Base radius<\/td>\n<td>1 \u2013 3 mm<\/td>\n<td>Sharp base: stress concentration and cracking<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 2 \u2014 Cavity geometry. The draw ratio limit is what constrains tall or bulky products.<\/p>\n<p>Holding features are worth designing deliberately. A rib that contacts the product on two sides plus a shaped base that stops it sliding gives a pack that survives a drop with a thin cavity wall. A cavity that is 2 mm larger than the product on every side needs a much thicker wall to achieve the same protection, which costs material and makes the pack harder to form.<\/p>\n<p>For a heavy product \u2014 a tool, a bottle, anything over about 300 g \u2014 the cavity needs a mechanical stop. The product's weight will bear on the seal in a pallet drop, and a seal that is asked to carry 300 g in shear will peel. A ledge in the cavity that the product rests on transfers that load into the blister body instead.<\/p>\n<h2 id=\"seal\">The seal: where blister packs fail<\/h2>\n<p>The seal is a heat-sealed bond between the blister flange and the coated card. It is 3 to 8 mm wide, it is made in under two seconds, and it is the single point of failure for the whole pack.<\/p>\n<table>\n<thead>\n<tr>\n<th>Parametro<\/th>\n<th>Typical setting<\/th>\n<th>Effect<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Seal temperature<\/td>\n<td>140 \u2013 180 \u00b0C<\/td>\n<td>Low: no bond. High: card scorch and blister distortion<\/td>\n<\/tr>\n<tr>\n<td>Seal pressure<\/td>\n<td>2 \u2013 4 bar<\/td>\n<td>Low: incomplete contact. High: crushed flanges<\/td>\n<\/tr>\n<tr>\n<td>Dwell time<\/td>\n<td>0.5 \u2013 2.0 s<\/td>\n<td>Short: weak bond. Long: charred card<\/td>\n<\/tr>\n<tr>\n<td>Seal width<\/td>\n<td>3 \u2013 8 mm<\/td>\n<td>Narrow: peel starts easily. Wide: more material, more heat<\/td>\n<\/tr>\n<tr>\n<td>Flange flatness<\/td>\n<td>Within 0.1 mm<\/td>\n<td>Wavy flange: gaps that do not seal<\/td>\n<\/tr>\n<tr>\n<td>Peel strength<\/td>\n<td>1.5 \u2013 3.0 N\/15 mm<\/td>\n<td>Below 1.5: opens in transit<\/td>\n<\/tr>\n<tr>\n<td>Coating weight<\/td>\n<td>3 \u2013 6 g\/m\u00b2<\/td>\n<td>Low: no bond. High: blocking and offset<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 3 \u2014 Heat seal parameters. All seven interact, which is why a seal problem is rarely one number.<\/p>\n<p>The failure modes are distinctive and each points at a different cause.<\/p>\n<p><strong>Peels cleanly with no fibre tear.<\/strong> The bond never formed. Either the temperature was too low, the coating was wrong for the blister material, or the coating had been contaminated.<\/p>\n<p><strong>Tears the card fibres.<\/strong> The bond is stronger than the card, which is what you want. A peel that takes paper with it is a good seal.<\/p>\n<p><strong>Seals on part of the perimeter only.<\/strong> Pressure is uneven, usually because the platen is not parallel or the flange is not flat. A wavy flange from a cold mould is the usual cause.<\/p>\n<p><strong>Seal looks good and fails in the cold chain.<\/strong> The coating became brittle at low temperature. Solvent-based coatings are more cold-flexible than some water-based ones, and the difference only shows at \u221220 \u00b0C.<\/p>\n<table>\n<thead>\n<tr>\n<th>Failure<\/th>\n<th>Causa<\/th>\n<th>Fix<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Clean peel, no fibre<\/td>\n<td>Temperature too low, or wrong coating<\/td>\n<td>Raise temperature, confirm coating compatibility<\/td>\n<\/tr>\n<tr>\n<td>Partial seal<\/td>\n<td>Uneven pressure or wavy flange<\/td>\n<td>Level the platen, flatten the flange<\/td>\n<\/tr>\n<tr>\n<td>Scorched card<\/td>\n<td>Temperature too high, or long dwell<\/td>\n<td>Lower temperature, shorten dwell<\/td>\n<\/tr>\n<tr>\n<td>Distorted cavity<\/td>\n<td>Heat conducted through the blister<\/td>\n<td>Cool the seal tool, shorten dwell<\/td>\n<\/tr>\n<tr>\n<td>Opens in a cold store<\/td>\n<td>Coating embrittled at low temperature<\/td>\n<td>Specify a cold-flexible coating<\/td>\n<\/tr>\n<tr>\n<td>Seal weak at one corner<\/td>\n<td>Flange too narrow there, or a radius<\/td>\n<td>Widen the flange, remove the radius<\/td>\n<\/tr>\n<tr>\n<td>Blister separates in retail<\/td>\n<td>Peel strength below 1.5 N\/15 mm<\/td>\n<td>Raise coating weight or seal temperature<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 4 \u2014 Seal failures. The first row is the one that gets misdiagnosed as a machine fault.<\/p>\n<p>The flange is the part of the design that most affects seal reliability and gets the least attention. It has to be flat, at least 3 mm wide, free of radius at the corners, and formed at a temperature that does not leave it wavy. A flange that is 2 mm wide with a 1 mm radius at each corner has almost no seal area at the corner, which is exactly where a peel starts.<\/p>\n<h2 id=\"card\">Card design and the retail interface<\/h2>\n<p>The card is not just packaging \u2014 it is the only place the product can be described, and it has a physical job as well.<\/p>\n<table>\n<thead>\n<tr>\n<th>Item<\/th>\n<th>Typical specification<\/th>\n<th>Perch\u00e9<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Board weight<\/td>\n<td>350 \u2013 450 gsm<\/td>\n<td>Below 300: too flimsy to stand on a peg<\/td>\n<\/tr>\n<tr>\n<td>Rivestimento<\/td>\n<td>Matched to the blister polymer<\/td>\n<td>The seal is a chemical bond, not a melt bond<\/td>\n<\/tr>\n<tr>\n<td>Print<\/td>\n<td>Reverse or surface, with a varnish<\/td>\n<td>Surface print needs a scuff-resistant varnish<\/td>\n<\/tr>\n<tr>\n<td>Card size<\/td>\n<td>Set by the retail fixture<\/td>\n<td>Pegboard pitch and shelf depth decide it<\/td>\n<\/tr>\n<tr>\n<td>Hanger hole<\/td>\n<td>6 mm dia, 12 \u2013 15 mm from the top<\/td>\n<td>The Euro hole standard<\/td>\n<\/tr>\n<tr>\n<td>Reinforcement<\/td>\n<td>Double thickness around the hole<\/td>\n<td>A single-thickness hole tears under the pack weight<\/td>\n<\/tr>\n<tr>\n<td>Barcode<\/td>\n<td>Quiet zone 3 mm minimum<\/td>\n<td>A barcode against print will not scan<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 5 \u2014 Card specification. The coating row is the one that has to be agreed with the blister material.<\/p>\n<p>The hanger hole is where a surprising number of packs fail. A 400 gsm card with a 6 mm hole and no reinforcement will tear through in a week on a peg, and the pack ends up on the floor. A doubled card, a plastic reinforcement ring, or a hole placed with 12 mm of material above it all solve the problem, and all cost a fraction of a cent.<\/p>\n<p>The card also has to be big enough for the legal content \u2014 warnings, ingredients, manufacturer details, recycling marks. On a small hardware item this is often the constraint that decides the pack size, not the product.<\/p>\n<h2 id=\"shelf\">Hanger holes, stacking and the shelf<\/h2>\n<p>A blister pack has to work on a pegboard, in a shelf-ready tray, or in a shipper, and each of those imposes a different requirement.<\/p>\n<p>On a pegboard the pack hangs from the hole, so the card has to be stiff enough not to curl and the hole has to be strong enough not to tear. Packs are hung two or three deep, which means the front pack carries the weight of the ones behind it.<\/p>\n<p>In a shelf-ready tray the packs stand on their base edge, so the card has to be stiff enough to stand up and the base edge has to be flat. A pack that curls forward will not stand, and the whole tray looks untidy.<\/p>\n<p>In a shipper the packs are stacked flat and the product's weight bears on the blister of the pack below. This is where a cavity that is too deep, or a product that is not located, produces crushed blisters in the middle of a case.<\/p>\n<h2 id=\"cr\">Child resistance and tamper evidence<\/h2>\n<p>Some product categories need the pack to be difficult to open, which is the opposite of the usual retail requirement and changes the design substantially.<\/p>\n<p>A child-resistant blister is usually a peel-and-push design: the user peels a corner of the lidding foil and then pushes the tablet through a tough film. The blister is made from a laminate with a paper or PET layer that resists pushing until it has been peeled, and the seal is stronger than a normal retail seal.<\/p>\n<p>For consumer goods, tamper evidence is usually achieved by a seal that cannot be reopened without visible damage \u2014 a card that delaminates when peeled, or a blister flange that tears the card. This is a property of the coating and the board, not of the forming, and it has to be specified at the same time as the seal strength.<\/p>\n<p>The tension is that a seal strong enough to be tamper-evident is also strong enough to be annoying, and a pack that customers damage while opening generates returns. The usual resolution is a peel tab: a small unsealed area at one corner that gives the user somewhere to start.<\/p>\n<h2 id=\"defects\">Defects and where they come from<\/h2>\n<table>\n<thead>\n<tr>\n<th>Difetto<\/th>\n<th>Causa<\/th>\n<th>Fix<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Hazy cavity<\/td>\n<td>Sheet too hot, or mould too hot<\/td>\n<td>Lower temperature<\/td>\n<\/tr>\n<tr>\n<td>Cracked corner<\/td>\n<td>Sharp radius, or too cold<\/td>\n<td>Open the radius, raise the temperature<\/td>\n<\/tr>\n<tr>\n<td>Wavy flange<\/td>\n<td>Mould too cold, or too fast a demould<\/td>\n<td>Raise mould temperature, slow the demould<\/td>\n<\/tr>\n<tr>\n<td>Thin base<\/td>\n<td>Draw ratio too high, no plug<\/td>\n<td>Add plug assist, reduce depth<\/td>\n<\/tr>\n<tr>\n<td>Product rattles<\/td>\n<td>Cavity too large<\/td>\n<td>Add locating ribs<\/td>\n<\/tr>\n<tr>\n<td>Seal fails at one corner<\/td>\n<td>Narrow flange, or radius<\/td>\n<td>Widen the flange<\/td>\n<\/tr>\n<tr>\n<td>Card tears at the hanger<\/td>\n<td>Hole too close to the edge<\/td>\n<td>Reinforce, or move the hole down<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 6 \u2014 Blister defects. Four of the seven are decided at the design stage rather than on the machine.<\/p>\n<div class=\"faq\">\n<h3>What material are blister packs made of?<\/h3>\n<p>Mostly PVC, at 0.3\u20130.8 mm. PETG is the common replacement where PVC is restricted, and PET, PS and PP are used for specific products. PVC dominates because it heat-seals to a coated card without treatment.<\/p>\n<h3>Why does my blister not seal to the card?<\/h3>\n<p>The coating on the card is formulated for a specific polymer. A PVC-coated card will not seal to a PETG blister. Check the coating compatibility before adjusting temperature.<\/p>\n<h3>How strong should a blister seal be?<\/h3>\n<p>1.5 to 3.0 N\/15 mm for most retail packs. A good seal tears card fibre when peeled; a bad one peels cleanly with no fibre transfer.<\/p>\n<h3>What is the maximum cavity depth?<\/h3>\n<p>About 1.5 times the cavity width for a reliable wall, and 2 to 1 is the practical limit. Beyond that the walls thin and the corners crack.<\/p>\n<h3>Why do blister packs crack at the corners?<\/h3>\n<p>Sharp radii combined with a sheet that is too cold. The material yields instead of flowing. Open the radius to at least 1.5 times the wall and raise the forming temperature.<\/p>\n<h3>What is a Euro hole?<\/h3>\n<p>A 6 mm diameter hanger hole positioned 12\u201315 mm from the top edge of the card. It is the standard for European pegboard retail.<\/p>\n<h3>Can blister packs be recycled?<\/h3>\n<p>The card and the plastic are different materials and are usually not separated by the consumer, which is the core problem. Mono-material packs and paper-based blisters are the current alternatives, both at higher cost.<\/p>\n<h3>Why does the product arrive loose in the pack?<\/h3>\n<p>The cavity is larger than the product and there is nothing to locate it. Add ribs or a shaped pocket so the product is held against the card on at least three features.<\/p>\n<\/div>\n<div class=\"cta\">\n<p class=\"cta-h\">Designing a blister pack that has to survive retail?<\/p>\n<p>Send the product drawing and tell us the retail fixture, the product weight and the market. We will design the cavity, specify the blister material and match the card coating to it.<\/p>\n<p><a class=\"btn\" href=\"https:\/\/uplastech.com\/it\/custom-vacuum-forming\/\">Talk to a blister packaging engineer<\/a>\n<\/div>\n<div class=\"rel\">\n<h4>Continue reading<\/h4>\n<ul>\n<li><a href=\"https:\/\/uplastech.com\/it\/pet-rpet-thermoforming\/\">PET and rPET Thermoforming<\/a><\/li>\n<li><a href=\"https:\/\/uplastech.com\/it\/polystyrene-thermoforming\/\">Polystyrene Thermoforming: GPPS, HIPS and Brittleness<\/a><\/li>\n<li><a href=\"https:\/\/uplastech.com\/it\/food-contact-thermoforming-compliance\/\">Food Contact Compliance for Thermoformed Packaging<\/a><\/li>\n<li><a href=\"https:\/\/uplastech.com\/it\/quali-prodotti-necessitano-di-confezioni-termoformate\/\">What Products Need Thermoformed Packaging<\/a><\/li>\n<li><a href=\"https:\/\/uplastech.com\/it\/form-cut-stack-inline-thermoforming\/\">Form-Cut-Stack: How an Inline Line Runs<\/a><\/li>\n<\/ul>\n<\/div>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>A blister pack is a cavity, a printed card and a seal, and the seal is what fails. Why PVC still dominates, and how to design a cavity that holds the product.<\/p>","protected":false},"author":1,"featured_media":7753,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Blister Packaging Design: Cavity, Card Seal and Retail Handl","_seopress_titles_desc":"A blister pack is a cavity, a printed card and a seal, and the seal is what fails. 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