Gemini has gained vast knowledge from years of developing blister packaging for the FMCG and pharma industries.

We can offer a complete design and prototype service through to pilot production. Using powerful 3D software, we create the blister design; from this information physical mock-ups can be produced, and accurate production costs can be calculated.

Blister packs are produced using a thermoforming process whereby plastic or film is heated and sucked against a mould. During the process the material stretches and becomes thinner. Predicting this thinning has always been left to experienced moulding companies to guess the outcome and often leads to costly tooling development.

At Gemini we use cutting-edge software that gives a highly accurate CAD model of the actual finished article without investing in any kind of tooling.

Blisters can be manufactured from different types of polymers which provide different features such as barrier, peelable, clarity, and FDA.

The blister may comprise a single layer (mono) or several layers of different polymer laminated together. The latter is most common as it is easier to process and offers superior performance.

We have close relationships with the leading manufacturers of these materials and select the most suitable for the application.

Blister Pack Process

Once the design is finalised the first stage is to produce a tool from the 3D CAD data; there are several different options depending on budget and quantity of blisters required.

  1. Machined from low density resin block – low cost; maximum yield: 20 blisters
  2. Machined from high density composite block –medium cost; maximum yield: 100 blisters
  3. Machined from tooling grade aluminium –high cost; maximum yield: 10,000 blisters

The tools are cut using a high-speed CNC machining centre to provide a perfect precision finish, ensuring parts are formed accurately. The blisters are then formed using a high definition vacuum forming machine whereby plastic or film is heated and sucked against the mould; this process is carefully controlled to ensure consistent results. The blisters are then filled and sealed with the appropriate product using a heated sealing machine which can be sealed in a range of materials. Finally, the blister packs are cropped to remove the excess material using a cutting press.

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