Blister Packaging 101: Definition, Types, and Benefits

In the cannabis industry, blister packaging can be an effective option, depending on your product. However, this may not fit your brand or product selection best. We invite you to follow along as we lay out everything you need to know about blister packs.

What is Blister Packaging?

Blister pack packaging is created by heating a plastic sheet and shaping it into a bubble or pocket, known as the “blister.” This encases the entirety of your product, allowing customers to see what they’re purchasing visually.

Traditionally, blister packaging has a cardboard back, known as “face seal blister.” The plastic blister sits in front of the cardboard and contains the product. On the cardboard are elements of your brand identity and other important information.

If your product has a consistent shape, you can uniformly shape the blister to match the product’s outline. However, if your product doesn’t have consistency, you can opt for other shapes (e.g., rectangular, oval, etc.).

Can You Use Blister Packs for Cannabis Products?

Some cannabis products incorporate blister card packaging. The most popular are vaping products, where the blister is made in the shape of a disposable vape pen or cartridge.

Some brands also incorporate blisters for concentrate items. Usually, the concentrate is in a transparent jar which is then blistered onto cardboard.

While you can get creative with your custom blister box, not all products will benefit from this type of packaging. For example, customers prefer flower and edibles in other packaging types, such as Mylar bags.

What are the Types of Blister Packaging?

Blister packaging can appear in the following ways:

Face Seal Blister

The plastic blister is shaped to fit around the product and then heat-sealed to a cardboard backing. This form of blister packaging is relatively cost-effective, making it ideal for high-volume products.

Full-Face Seal Blister

The blister encases both the product and the card backing entirely. The plastic is secured to the card either by heat sealing or by sliding it through extra plastic reinforcements on the sides.

This design enhances the packaging’s durability, by making the corners more resistant to bending while also improving their appearance.

Full Card Blister

Similar to a full-face seal blister, this packaging covers the entire card. However, instead of being heat-sealed, it features flanges that wrap around the edges of the card. The card is slid into position and occasionally secured with staples.

Trapped Blister

A trapped blister is similar to a traditional blister pack, but with an added layer of cardboard in front of the plastic, shaped to fit around the blister. This design secures the plastic between the two pieces of cardboard, with the top layer die-cut to hold the product snugly.

Since it doesn’t rely on heat-sealing, this method is more cost-effective. It also enhances tamper resistance, as any attempt to remove the product visibly damages the outer cardboard. Additionally, it offers a more polished appearance by minimizing exposure to plastic.

Clamshell

Clamshell packaging, also known as clam packaging or clam packs, replaces the cardboard backing with a hinged plastic design, connected at the side or the base. Some clamshells are crafted to stand upright on store shelves, while others include a hole for hanging on racks.

They can feature a snap-close button or be heat-sealed for added security. The plastic bubble may have a uniform shape on both sides or vary in size and form to accommodate the product inside.

Pros and Cons of Blister Packaging

If you run a cannabis business and are considering blister packs for your products, here are some things to consider:

Pros

• Eco-friendly – All blister packs are made with plastic and cardboard, both recyclable materials.
• Lightweight – Blister and clam packaging are very lightweight, reducing transportation costs.
• Protection – Blister packs protect the product from damage and keep it clean. They also reveal tampering, unlike boxes that can be opened and reclosed unnoticed.
• Theft Protection – Designed in unique shapes, making it difficult for shoplifters to conceal.
• Visually Appealing – Blister packs showcase the product directly, catching the customer’s eye and making it stand out compared to boxed items.

Cons

• Plastic Waste – While plastic is recyclable, if consumers are not mindful, blister packs can create a lot of waste.
• Time-Intensive Production – Takes longer to manufacture than other packaging options.

Final Word

Blister packaging is a very effective option for certain cannabis products, such as vape pens and cartridges. This is thanks to the fact that it gives your product transparency other brands may not offer.

Interested in using blister packs for your next product? Not sure where to begin? Custom 420 is here to help! We invite you to reach out through our contact form to learn more.

Frequently Asked Questions