Custom Blister Packaging

Products That Suit Custom Blister Packaging

Blister packs work best for small, solid items that benefit from being seen. Anything that would get lost in a box, or that a customer wants to inspect before buying, is a good candidate.

Very heavy items or products with sharp points may need a double blister or a thicker card back to stop the pack tearing at the peg hole. Tell us the weight of your product and we will specify accordingly. Small items with a cord or cable are often better in printed hanger boxes, where the cable can be coiled behind a window.

• Small hardware such as hooks, hinges and fixings
• Phone accessories, cables and chargers
• Batteries, bulbs and small electrical parts
• Fishing tackle, lures and hooks
• Hair accessories, cosmetics and nail care
• Toys, collectable figures and stationery
• Car accessories, keyrings and gadgets

Shaping the Blister Around Your Product

Each blister is formed over a mould made to the shape of your product. A close-fitting blister holds the item still and looks neat, while a slightly roomier one leaves space for accessories or instructions. Products with awkward shapes, such as a curved handle or a set of parts, may need a blister with several cavities.

The clear plastic can be made in different thicknesses. Thin material is fine for light items like hair clips, while heavier products need a thicker, stiffer blister that will not dent when handled. For the clearest view, choose a crystal-clear material and avoid deep draws, which can stretch the plastic thin at the corners.

Send us a sample of the product, or detailed drawings with measurements, and we will create a mould design to show on the proof. The sample we ask for is the same one described in the product measuring guide, and it saves a second mould.

Designing the Card Back

The front of the card frames the product, so leave space where the blister will sit and plan your graphics around it. Put the logo and product name above the blister, near the hang hole, where shoppers look first. Use the space below for key benefits or a short description.

The back of the card carries the detail: instructions, specifications, warnings, barcode and any regulatory text your product needs. Keep it organised and readable, as shoppers often turn the pack over before deciding.

Card weight matters too. A heavier board, often 350 to 450 gsm, keeps the pack flat and stops it curling or tearing at the hang hole. A coated card with a gloss or matt varnish looks clean and resists marking. The card must be suitable for heat sealing, which we take care of when specifying the material.

Clear, simple illustrations of the product in use can do more than a paragraph of text. A small drawing showing how a bracket fits or how a cable connects answers the question a shopper is asking before they reach for their phone to search. Full-colour card backs print the same way as full colour printed boxes, with the blister footprint masked on the proof.

Hang Holes, Peg Displays and Shelf Ready Options

The most common hang hole is the euro slot, a shape with a central hole and wings that fits most retail pegs. A round hole is used on some displays. Make sure the hole is placed so the pack hangs straight once the product is inside, which means positioning it over the product's centre of weight.

If you supply retailers, check their display requirements before printing. Some chains need a specific hole shape or card size, while others ask for a particular barcode position. If your product will also sit on a shelf, a folded card base can let the pack stand upright as well as hang.

We can also supply printed counter display boxes or shelf trays to hold your blister packs at the till, which helps new products get noticed.

Send the Product Before Asking for a Price

A blister is moulded around the real thing, so the quickest route to an accurate price is to post us one product, or two if the range has a large and small version. We measure it, decide the blister depth and the card size around it, and tell you whether a face seal or a trapped blister suits it. Guessing from a drawing usually means a second mould, which costs more than the postage.

With the sample, tell us how you plan to seal the packs, where they will be sold and how many you need, and we reply by email with a quote within one working day. The proof shows the card artwork with the blister outline drawn on it, so you can see what the plastic will hide. Packs are produced in 4 to 7 working days after approval and delivered free by tracked courier within UK mainland; dented blisters or print faults reported within 10 days are reprinted or refunded. Products too thick for a blister usually move to clear clamshell boxes with printed inserts.