Introduction to Custom Blister Packaging
Custom blister packaging represents one of the most versatile and widely-used forms of product packaging across countless industries.
This style of packaging, featuring a plastic bubble or cavity molded to the shape of your product and sealed to a printed card or backing, provides excellent product visibility, theft deterrence, and promotional opportunities.
Our custom blister packaging solutions help your products stand out on retail shelves while providing practical benefits for manufacturers and retailers alike.
At Teal Packaging, we specialize in custom blister packaging that balances product protection with marketing impact. The transparent plastic bubble allows customers to see your actual product, building purchase confidence through visual confirmation of quality.
The printed card backing provides substantial space for branding, product information, and marketing messages that influence purchasing decisions.
Whether you sell electronics, hardware, cosmetics, toys, health products, or consumer goods, our custom blister packaging solutions can be tailored to your specific requirements. We work with manufacturing partners who produce high-quality packaging that meets industry standards while delivering the visual appeal your brand deserves.
The combination of product visibility and print space makes blister packaging one of the most effective retail packaging formats available.
Materials and GSM Specifications
Custom blister packaging materials are selected based on product requirements, display environment, and budget considerations.
Our solutions use quality materials that provide appropriate protection while enabling attractive presentation and efficient production.
The plastic bubble component of custom blister packaging typically uses PVC (polyvinyl chloride) or PET (polyethylene terephthalate) films. Standard gauge ranges from 10-12 mil (0.010-0.012 inches) for lightweight products to 16-20 mil for heavier items requiring more robust protection.
PET offers superior clarity and environmental credentials compared to PVC, making it the preferred choice for brands prioritizing sustainability.
The card backing uses 12-16 point (250-350 GSM) paperboard that provides rigidity and print quality. Premium applications may use 18-24 point (350-450 GSM) SBS (solid bleached sulfate) paperboard that creates a more substantial feel.
For hang tab applications requiring additional strength, 16-16-16 triplex board (approximately 400 GSM total) provides exceptional durability. All materials can be available with FSC-certified paper options by specification upon request.
Customization Options
Custom blister packaging offers extensive customization opportunities to create distinctive packaging that reflects your brand identity and captures consumer attention.
Our production capabilities transform functional packaging into powerful marketing tools.
The printed card backing provides substantial space for full-color graphics, product photography, brand messaging, and regulatory information.
We offer offset printing for precise color matching and complex designs, digital printing for short runs, and flexographic printing for large quantities. Finishing options include:
- Gloss or matte lamination
- Spot UV coating
- Foil stamping that add premium appeal
Blister shape and style can be customized to match your product perfectly. Options include:
- Face seal blisters where the plastic is sealed to the front of the card only
- Full seal blisters where plastic surrounds the product on all sides
- Clamshell designs with hinged closures. Hang tab configurations include standard euro slots
- Retail hook slots
- Punched holes
Custom die cuts in the card create distinctive shapes that stand out on retail displays.
Available Sizes in Inches
Custom blister packaging sizes are determined by product dimensions and packaging requirements.
Our production capabilities accommodate a wide range of sizes, from small electronic components to larger consumer products.
Small blister packages start at 2 x 2 inches, suitable for small hardware, batteries, and electronic components. Medium sizes at 4 x 6 inches, 5 x 7 inches, and 6 x 8 inches accommodate typical cosmetics, tools, and consumer products. Larger sizes at 8 x 10 inches, 9 x 12 inches, and 10 x 14 inches fit bigger products including:
- Larger tools
- Hobby items
- Multi-piece sets
Custom sizing is available for unique product dimensions.
Our engineering team can design blister cavities that match your exact product specifications, ensuring secure fit and optimal product protection. We recommend allowing minimum 0.125 inches clearance around all product dimensions for proper sealing and to prevent product damage during shipping and handling.
Sustainability Commitment
Teal Packaging is committed to providing sustainable blister packaging options that address growing environmental concerns while maintaining the functionality and visual appeal that make this packaging format effective.
We offer solutions that reduce environmental impact without compromising performance.
For brands prioritizing sustainability, we offer PET (polyethylene terephthalate) blisters that are available with recyclable options by specification, unlike PVC which has limited recycling options.
Our paperboard backings are available with FSC-certified paper options by specification, ensuring responsible forestry practices.
We offer recycled content options including 30% to 100% post-consumer waste materials.
For brands seeking complete compostable solutions, we provide biodegradable blister options made from plant-based materials that break down in commercial composting facilities. These sustainable alternatives meet international environmental standards while maintaining the product visibility and protection that make blister packaging effective.
We continue to invest in research and development of new materials that reduce environmental impact.
How to Order
Ordering custom blister packaging from Teal Packaging is straightforward with dedicated support throughout the process.
Our team guides you from initial consultation through production and delivery, ensuring you receive packaging that meets your exact specifications.
Begin by sharing your product dimensions, quantity requirements, display requirements, and any special features needed.
Our packaging specialists provide recommendations based on your specific products and distribution channels. You will receive material samples and proofs for approval before production begins, ensuring complete satisfaction.
Minimum order quantities start at 50 units, making blister packaging accessible for businesses of all sizes. Production typically requires two weeks from proof approval. free shipping are confirmed during quoting is included.
Our design team provides complimentary artwork preparation and optimization services.
What products are suitable for blister packaging?
these boxes works well for virtually any small to medium-sized product including:
- Electronics
- Hardware
- Cosmetics
- Toys
- Health
- Beauty products
- Office supplies
- Consumer goods
The product visibility makes it particularly effective for items where visual confirmation influences purchasing decisions.
How is the blister sealed to the card?
Blisters are sealed to the card using heat sealing technology that bonds the plastic film to the paperboard. This creates a tamper-evident seal that protects products from pilferage while maintaining product visibility.
The seal strength can be adjusted based on your requirements for ease of opening versus theft deterrence.
Can blister packaging be recycled?
PET blisters are widely recyclable through standard recycling programs. Paperboard backings can be recycled with other paper products. We also offer biodegradable blister options for brands seeking compostable alternatives. Check your local recycling guidelines for specific acceptance in your area.
What is the difference between face seal and full seal blisters?
Face seal blisters have plastic sealed only to the front of the card, with the back remaining exposed. Full seal blisters have plastic sealed around the entire product perimeter, providing superior product containment and theft deterrence. Full seal blisters are recommended for high-value items and products requiring maximum protection.
What is the minimum order quantity?
Minimum order quantity is 50 units, making your packaging accessible for businesses of all sizes. For very small production runs, we can discuss economical options to meet your needs without excessive setup costs.
