Blisters are a highly advantageous type of packaging design, but that doesn’t mean they’re perfect. While blister packaging is a popular choice for a wide range of industries and applications, there are a few disadvantages that anyone considering this design should consider.

Blister Packaging Requires a Backing

Think of blister packaging as half of a plastic shell—open on one side, it is usually sealed shut with a foil or cardboard backing. In many cases, this is actually considered an advantage. Foil backing is perfect for pharmaceutical applications, as it allows users to push medication through the foil—this is senior-friendly and child-resistant. In other cases, a cardboard backing provides not only security, but a broad, flat surface, ideal for printing graphics and/or instructions.

Despite the practical and aesthetic advantages of the backing, it comes with one minor disadvantage, which is that it requires a sealing process to attach to the plastic. That aside, though, the backing card or foil is generally quite useful.

Advantages of Blister Packaging

While the necessity of a sealing process may be viewed as a negligible disadvantage, blister packaging offers a number of advantages that more than make up for it. Thermoformed around your product to hold it in place, this type of packaging is generally made from PET or PVC, giving consumers a crystal-clear window to what’s inside.

Other advantages of this design include:

  • Blister packaging is a highly cost-effective solution.
  • It is well-suited for display, either hanging on a peg or standing on a shelf.
  • In the hands of a talented thermoformer, it can be as small as medication packaging or as large as a suitcase.
  • It allows you to pack multiple items in the same package.
  • Blister packaging can be very tamper-evident.

With these and other advantages, blister packaging is a deservedly popular style, even though it requires a secondary heat-sealing operation. This goes to show that when working with a product like blisters, the pros can very easily outweigh any potential cons, and make for a low-cost, highly appealing solution.