Blister packaging: a comprehensive guide to types, materials, and benefits

Blister packaging is a clear plastic shell that holds and protects a product. It is used in retail to keep items safe, easy to display, and tamper-resistant. Two common types are sealed blister packs, which attach to a card back, and clamshells, which fold shut. PET and rPET are preferred materials in Europe because they are clear, strong, and recyclable.

• Blister packaging shows the product clearly while protecting it from damage and theft.

• Sealed blisters are best for light, single items, while clamshells suit heavier or multi-part goods.

• PET is the main material used because it meets recyclability and strength goals in Europe.

• rPET supports sustainability by using recycled content and lowering overall carbon impact.

• Thermoforming allows fast, repeatable production of blister packs in many shapes and sizes.

What is blister packaging?

Blister packaging is a rigid plastic shell made to fit the shape of a product. It is formed around the item to hold it in place and protect it. In a sealed blister pack, the plastic seals to a printed card. In a clamshell, the two plastic halves close together. Both styles help show products clearly and keep them safe during transport or on store shelves.

This packaging is often used for small goods like phone chargers, makeup tools, USB drives, or screws. Clear visibility helps shoppers see exactly what they are getting, which can reduce returns or damage claims.

Two common formats: sealed blisters and clamshells

Blister packaging usually comes in two types: sealed blister packs and clamshells. Each works best for different product shapes or retail needs.

Sealed blister: This design uses a clear cavity sealed to a printed paperboard card. It is often used for light, single items like pens or personal care tools. The back card adds space for branding, text, or instructions. The sealing process also makes packs tamper-evident and more secure.

Clamshell: Made from two plastic halves that close and can often be reopened. Clamshells suit heavier or multi-part items like earbuds, screw kits, or grooming sets. They allow full product viewing and sometimes reuse. This format is practical for grouped products or items needing more support.

You can view our clamshell packaging options sized for common retail items and ready to seal.

Why PET is now the standard for blister packaging in Europe

PET, short for polyethylene terephthalate, is now widely used for blister packaging in Europe. It offers high transparency, good strength, and is accepted in most recycling systems. PET provides a balance between visibility and protection, which makes it ideal for retail use.

Earlier, PVC was used more often, but it disrupts recycling systems and can release harmful waste. This has led many suppliers and brands to switch to PET. Its clear and strong structure keeps products secure while helping companies stay compliant.

The role of rPET in sustainable blister packaging

rPET is recycled PET made from post-use materials like bottles or food trays. It looks and performs like original PET but requires less energy to make. This helps reduce emissions and supports brand goals around carbon reduction and circular use of materials.

The use of rPET depends on local recycling supply, but it is expanding. Many retailers now prefer rPET to show their commitment to sustainability. Clear recycled content also improves packaging scores under many EU assessments.

What makes blister packaging effective at retail

Effective blister packaging offers strong product display, protection, and easy shelf handling. The clear front shows the item inside, which helps with shopper decisions. The rigid shell stops the product from bending, scratching, or falling apart. Some designs also include hanging holes so the pack can hang on a peg in store.

PET blister packs give extra protection. They help seal out dust and moisture and show signs if the pack has been opened. This improves safety and customer trust in the product’s condition.

Legal and sustainability factors in Europe

New packaging rules in Europe require simple, recyclable designs made from one material. PET and rPET meet these goals. They are easy to recycle and can be made in thinner layers while keeping strength. This helps reduce plastic use and lower shipping weight, which cuts costs and carbon emissions.

PVC or other mixtures that are hard to recycle are now discouraged. Switching to PET-based formats helps brands stay ahead of compliance needs and reduce audit risks.

How PET blisters are made: thermoforming explained

Thermoforming is the process used to shape PET blister packs. A PET sheet is heated until it becomes soft, then pressed over a mold using air or a vacuum. Once it cools, it keeps that shape permanently.

This method works well for large quantities and gives consistent results. We use thermoforming to create packs with precise sizes and clean finishes. These can be sealed and shipped quickly with no extra steps.

Choosing between sealed blisters and clamshells

The right blister pack depends on how the product is used, its shape, and how it will be displayed.

Sealed blisters: Good for flat, small items with fixed branding. They are tamper-resistant and take up less shelf space.

Clamshells: Better for heavier, reusable, or multi-item sets. They are resealable and allow full product visibility from both sides.

To choose and order PET clamshell formats, explore our range of clamshell packaging.

Practical buying tips for blister packaging: fit, visibility, and operations

Here are some useful things to check when selecting blister packs:

• Product fit: Choose a cavity size close to your product shape. This prevents slipping and reduces waste.

• Wall strength: Pick a thickness that protects without using too much plastic.

• Transparency: A clear, polished surface improves product visibility.

• Sealing options: Use a simple heat sealer if you need to run small batches in-house.

• Storage and shipping: PET packs are light and stackable, which saves space and cost in your supply chain.

Blister packaging for hygiene and retail display

While blister packaging is not used for medicine or pharmaceutical tablets, it is a strong choice for retail medical accessories. Items like scissors, tweezers, and thermometers stay visible and sealed from outside contact. This makes them easier to inspect before use and helps confirm they are clean and complete.

Choosing blister packaging for speed and clarity

PET and rPET blister formats help brands move faster and stay compliant. They provide clear product views, reduce tampering, and are accepted by most recyclers. Because many options are stock formats, companies can avoid delays linked to custom pack design. This supports faster product launches and simpler operations.

If you need help choosing the best option, want to check sizing, or have sealing questions, please contact us.