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Spanish What Is a Blister Pack?
Blister packaging is a common form of retail and pharmaceutical packaging in which a pre-formed plastic cavity (the blister) holds a product and is sealed to a backing card or foil. The choice of blister packaging materials is critical: it determines how well the package protects the product, how it looks on the shelf, and its cost and environmental impact. Well-chosen blister materials can ensure durability, barrier protection, and clear visibility of the product. For example, blister packs are prized for their protection (shielding products from moisture, oxygen, and contamination), visibility (transparent film lets consumers see the product), tamper evidence, and even dosage management in pharmaceuticals.
- Protection: Blister packs shield products from moisture, oxygen, and contaminants.
- Visibility: Clear plastic allows consumers to view the product without opening the package.
- Tamper Evidence: Any attempt to open the seal is obvious, preserving safety.
- Dosage Accuracy (Pharma): Blisters help patients take the correct dosage at the right time.
A typical blister pack consists of a thermoformed plastic cavity attached to a backing substrate (often cardboard or aluminum foil). In thermoformed blister packaging, manufacturers commonly use rigid, transparent polymers that offer strength and barrier properties. Common blister materials include Polyethylene Terephthalate (PET), Polyvinyl Chloride (PVC), Polyvinylidene Chloride (PVDC), Polychlorotrifluoroethylene (PCTFE), and Cyclic Olefin Polymer (COP). Each material has unique properties (clarity, stiffness, barrier performance, cost, etc.) that suit different applications. We examine each of these materials in detail below.
Polyvinyl Chloride (PVC)
Polyvinyl chloride (PVC) is one of the most widely used blister packaging materials. PVC is favored for its excellent clarity and low cost. It is easy to thermoform into complex shapes, making it ideal for large-scale production. Because of its transparency and smooth finish, PVC showcases the product attractively. In addition, PVC provides a basic barrier against moisture and oxygen, which is adequate for products with moderate shelf-life needs.
- Advantages: PVC is very inexpensive and offers high clarity, enhancing product visibility. It is easy to thermoform, allowing cost-effective production of various shapes.
- Limitations: PVC has limited moisture and oxygen barrier, so it is not ideal for long-term storage of highly sensitive goods. It also raises environmental concerns: PVC contains chlorine, complicating recycling and disposal.
Despite its limitations, PVC remains popular. As Complete Packaging Solutions notes, “PVC is the most popular blister material because it’s the cheapest”, though industry trends are gradually shifting toward more eco-friendly alternatives like PET. In practice, PVC blisters are often combined with other polymers or coatings (e.g. PVDC) to improve performance for more sensitive products.
Polyethylene Terephthalate (PET)
Polyethylene terephthalate (PET) is another very common blister material. PET offers excellent clarity and high strength, giving the package a premium look and feel. Compared to PVC, PET has superior gas-barrier properties, making it better at keeping oxygen out. Importantly, PET is fully recyclable, and most curbside recycling programs accept PET and recycled PET (rPET) easily. This recyclability has made PET a favorite in markets focused on sustainability.
Advantages: PET’s superior transparency makes products stand out on the shelf. It provides a good barrier to oxygen and gases (better than PVC) and is recyclable.
Limitations: PET is generally more expensive than PVC. It also has a somewhat weaker moisture-barrier than specialized materials and requires higher processing temperatures.
Because of its clarity and eco-friendly image, PET is often used where product appearance and sustainability are priorities. Blister packs made from PET are clear and sturdy, and brands can even source recycled-PET (rPET) sheets. Yundu Filling Machinery notes that PET (and rPET) are “the easiest to recycle” and accepted by most programs, reinforcing PET’s advantage for green packaging.
Polyvinylidene Chloride (PVDC)
Polyvinylidene chloride (PVDC) is usually not used by itself as a rigid blister but as a coating layered onto PVC. PVDC dramatically enhances the barrier properties of PVC blisters. It provides excellent protection against moisture and oxygen, greatly extending the shelf life of perishable goods. For example, PVDC-coated PVC is the standard in pharmaceutical blisters, helping keep drugs stable by preventing “oxygenation or excess moisture”.
Advantages: PVDC offers a superior moisture and gas barrier when laminated with PVC, extending product freshness and shelf life. It maintains transparency when coated, so visibility is preserved.
Limitations: PVDC materials are more expensive than plain PVC. It also raises environmental concerns (like PVC) and can complicate recycling.
In practice, PVC/PVDC laminates are widely used for food and medical blisters. The PVDC layer is usually very thin, added to the PVC blister sheet. This hybrid approach takes advantage of PVC’s formability and PVDC’s barrier. According to industry sources, PVDC “is frequently joined with PVC sheets to create an extra layer of protection” against moisture/oxygen. For products that require the highest barrier protection (e.g. sensitive pharmaceuticals, herbs, or certain electronics), PVC-PVDC is often the material of choice.
Polychlorotrifluoroethylene (PCTFE)
PCTFE is a specialty polymer known for its exceptional moisture-barrier properties. Blister film made from PCTFE (often sandwiched between PVC sheets) is used when keeping products absolutely dry is crucial. For instance, medicines that degrade in humidity, or sensitive electronic components, may be sealed in PCTFE laminates. Complete Packaging Solutions describes PCTFE blisters as “a laminated blister package used to form a barrier around a product, keeping it dry and moisture-free”. PCTFE’s moisture transmission is extremely low – much lower than PVC or PET – so it prevents almost all water vapor from passing through.
Advantages: PCTFE has an excellent moisture barrier (better than most other plastics). It also resists many chemicals while remaining clear. This makes PCTFE blisters ideal for pharmaceuticals and any moisture-sensitive items.
Limitations: PCTFE is much more expensive than standard blister polymers. It is also less flexible, which can limit the depth or shapes of blisters, and requires specialized processing equipment.
Because of its cost, PCTFE is used only when necessary. When maximal moisture protection is needed, manufacturers may laminate a layer of PCTFE film into the blister. This laminated PCTFE layer “offers less water vapor permeability” than PVC alone. In summary, PCTFE-based blisters provide a premium, high-barrier option for the most demanding applications in pharmaceuticals and beyond.
Cyclic Olefin Polymer (COP)
Cyclic olefin polymers (COP) are a family of high-performance plastics used in blister packaging when high clarity and barrier are needed. COPs (often similar to cyclic olefin copolymers like COC) offer very high transparency and good moisture resistance. They are often used for medical products, diagnostics, or cosmetics where a crystal-clear view of the product is a priority. COP is sometimes blended with other plastics (e.g. polyethylene or polypropylene) to achieve deeper cavity shapes without sacrificing clarity. For example, COP is frequently used in the medical field because it can be combined with PP to produce strong, deep-formed blisters for medicines.
Advantages: COP films are extremely clear, giving a glass-like appearance. They also provide a good moisture barrier and excellent chemical resistance. This makes COP blisters attractive for premium products that must remain visible and protected.
Limitations: COP materials are relatively costly. They have limited resistance to certain solvents and require precise forming conditions.
In practice, COP is used selectively for high-end packaging. A small percentage of blister packs may use COP, especially in applications like high-purity pharmaceuticals or electronics components. Its high clarity can be a selling point, but the higher material cost means it is used only when the benefit justifies the expense.
Choosing the Right Blister Packaging Material
When selecting a blister packaging material, manufacturers must consider several factors beyond just the material properties. Key considerations include product sensitivity, cost, sustainability, and regulatory requirements:
Product Sensitivity
Products like pharmaceuticals, medical devices, or moisture-sensitive foods need strong barrier properties against water vapor, oxygen, and light. In those cases, high-barrier materials like PVDC-coated PVC, PCTFE laminates, or COP may be needed. For less sensitive items (e.g. toys or hardware), the basic protection of PVC or PET may suffice.
Cost
High-performance polymers (PCTFE, PVDC, COP) are more expensive. If budget is limited and barrier requirements are moderate, manufacturers often choose PVC or PET, which are more economical. As one source notes, “PVC and PET are more budget-friendly options, making them suitable for products with less stringent requirements”.
Environmental Impact
Sustainability is increasingly important. Materials like PET (especially recycled PET) are more eco-friendly and widely recyclable. In contrast, PVC (and its laminates) is less recyclable and has higher environmental impact. Many brands now prefer PET or other recycled plastics for greener packaging.
Regulatory Compliance
Pharmaceutical and food packaging must meet strict regulations (FDA, EMA, etc.). These standards often require certain barrier levels and material approvals. Blister materials must be FDA-approved for their intended use. For example, the pharmaceutical industry often demands proven materials like PVC/PVDC or PCTFE laminates for patient safety.
By balancing these factors, companies can choose a blister material that best matches their product and market needs. For instance, a tablet blister might use PVC/PVDC to keep pills dry (fulfilling FDA shelf-life standards), while a low-cost consumer gadget might use plain PET blister for visibility and recyclability.
Conclusion
Blister packaging materials range from inexpensive PVC to high-performance polymers like PCTFE and COP. Each material type offers a distinct combination of clarity, barrier protection, formability, and cost. Polyvinyl chloride (PVC) remains the most common due to its clarity and low cost, but PET is increasingly popular for its strength and recyclability. When additional barrier is needed, PVDC coatings or PCTFE laminates can be used. COP provides ultra-clear, high-barrier packaging for premium products.
Ultimately, choosing the right blister packaging material means matching the polymer’s properties to the product’s needs – ensuring the package keeps the product safe and fresh, appeals to customers, and meets cost and environmental goals. Packaging professionals should consider all these factors to select the optimal blister material for each application.
Types of Blister Packaging Materials FAQ
Transparency is the cornerstone of our Yundu team, so here are the most common questions and answers we receive surrounding our blister packaging materials.
Polyvinyl chloride (PVC) is the most common due to its low cost, ease of thermoforming, and high clarity for product visibility.
Blister packs typically use rigid plastics such as PVC, PET, PP, or PETG, selected for formability, clarity, and barrier properties.
Yes. PVC is widely used because it’s inexpensive, easy to mold, and provides good clarity, though it has moderate barrier performance.
The four most common thermoforming plastics are PVC, PET, PP, and PETG, chosen for their combination of formability and clarity.
Manufacturers often use PVC or PET for standard blisters; higher‑barrier applications may use PVDC‑coated PVC or PCTFE laminates.
PET offers superior strength, excellent clarity, better oxygen barrier than PVC, and is widely recyclable, making it ideal for premium sustainable packaging.
PVDC enhances PVC’s barrier against moisture and oxygen, extending shelf life—especially critical for food and pharmaceutical applications.
Choose PCTFE laminates when maximum moisture protection is required, such as for humidity‑sensitive pharmaceuticals or electronic components.
Cyclic olefin polymers (COP/COC) are used for ultra‑clear, high‑barrier blisters in medical or cosmetic packaging where product visibility is paramount.
Evaluate product sensitivity, barrier needs, cost, sustainability goals, and regulatory requirements; match these factors to each material’s properties.
