Blister Pack Development

Gemini has gained vast knowledge from years of developing blister packaging for the FMCG and pharma industry. We can offer a complete design & prototype service to pilot production.

Using powerful 3D software we can 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 will give us 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 polymer which provide different features such as barrier, peel able, clarity, and FDA.

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

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




 blisterpack bottomBlister 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 - max yield 20 blisters

2. Machined from high density composite block - medium - max yield 100 blisters

3. Machined from tooling grade aluminium - high - max yield 10,000 blisters

The tools would be cut using a high speed CNC machining centre to provide a perfect precision finish to ensure 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.