Product family 04
Blister packaging and thermoformed trays
Sheet plastic formed over a tool so the product sits in a cavity cut to its exact shape. Used for hardware, personal care and small electronics where the customer has to see the item, or where an insert has to hold it still through a courier network.
Specifications
Material, tooling and what each costing step buys.
| Parameter | Range we produce | Notes |
|---|---|---|
| Material | PET, PVC, recycled PET (rPET), PP | rPET needs a clean flake supply; availability moves the price |
| Sheet thickness | 0.3 / 0.4 / 0.5 / 0.6 / 0.8 mm | Below 0.3 mm the cavity walls go floppy in transit |
| Cavity depth | Up to 60 mm from the sheet plane | Deeper draws need a plug-assist tool |
| Format | Blister on printed card, clamshell, tri-fold, tray, lid and tray, skin pack | Card is 300–400 gsm with a heat-seal coating |
| Tooling | Aluminium form tool, 10–12 working days | One tool per cavity layout, reused on every reorder |
| Printed card in offset CMYK; direct print on the plastic on request | The card carries the artwork in most programs | |
| Sealing | Heat seal, radio frequency, or a folded and stapled card | Seal strength is checked on the pre-production run |
| MOQ | 3,000 pcs for a new tool; 1,000 pcs on an existing cavity | Tooling is quoted once, amortised across reorders |
| Sampling | 10–12 working days including the form tool | Includes a fit check with your actual product if shipped to us |
| Production lead time | 20–30 days after sample sign-off | Printed cards add 5–7 days |
| Packing | Nested in 5-ply cartons, counts per carton stated on the label | Nesting reduces volume but increases handling care |
Tooling is the number that surprises first-time buyers. It is quoted separately, it is yours, and it is only worth paying once you expect to reorder.
Where a formed pack is the right answer
- Hardware and toolsBits, blades and fittings that must not move
- Personal careDevices and refills sold where the product is visible
- Small electronicsCable kits and accessories with a fixed cavity layout
- Retail pegboardHang-tab formats for store fixtures
Where plastic will cost you more than it saves
- EU single-use rulesSome formats are restricted by market; check before the tool is cut
- Low volumeUnder 3,000 pcs the tool dominates the unit price
- Brand-led productsA pulp or paperboard insert sells the story better
- Heavy itemsAbove 2 kg the seal or the card fails before the plastic does
If your market bans the format, we will say so before quoting a tool. A paperboard insert or a moulded pulp tray is often the answer, and we make both.
Sampling
Request a blister or tray sample.
Send a photo of the product next to a ruler, its weight, and the market. For a new cavity we cut the tool and form a sample so the fit is checked on the real item, not on a drawing.
Tooling cost is quoted with the sample and credited against the first order of 10,000 pcs or more.
- Phone+86 188 1391 9413
- Emailcrystal1319@163.com
Questions we answer daily
Blister packaging FAQ
PET or PVC — which one should I specify?
PET is clearer, stiffer and the recyclable code 1 stream, which matters in Europe and Japan. PVC forms more easily around awkward shapes and seals to card at lower temperature, but it is code 3 and increasingly rejected by retail programs. If the shape allows it, specify PET.
Is the tooling mine or yours?
The tool is paid for by you and kept for your program. We store it and maintain it between runs, and we do not use it for another client. If you move production, the tool can be shipped to you or to the new supplier.
How does this work with the EU packaging rules?
Restrictions differ by format and by member state, and they change. We tell you which material and format we can supply and what documentation the material supplier provides; confirming compliance for your specific market remains your call, and we would rather flag that than give you a blanket assurance.
Can the product be visible without a plastic shell?
Yes. A die-cut window in a folding carton, or a moulded pulp tray with a printed sleeve, gives visibility without the plastic. For hardware we often end up quoting a paperboard insert against the blister so the cost and the recycling story sit side by side.
What happens if the product changes next season?
A small change in one dimension can sometimes be taken up by a new card cut rather than a new tool. A change in the product's silhouette means a new cavity and a new tool, which is why we ask for the product drawing or a physical sample before quoting.
Plastic shell or paperboard insert?
Send the product and the market. We will quote both options with the tooling cost separated so the comparison is honest.