Blog

Thermoforming is inclusive of many types of packaging including blisters, clamshells, tri-folds, and trays.

Blister packaging is comprised of a thermoformed plastic part (blister) and a printed paperboard backing (blister card).

The following content includes descriptions of the most common material types, including their uses and design strengths, and other key considerations for your packaging project.

PVC (Polyvinyl Chloride) is most versatile packaging material we offer and is easily fabricated, bonded, or welded. PVC is characterized by excellent mechanical toughness, chemical and weather resistance, and flame retardant properties. PVC has more elasticity than other materials, allowing it to form well, die-cut easily, and provide better de-nesting. The elasticity also means PVC is more flexible than and not as brittle as PET. PVC can be identified by the #3 recycle symbol.

Heat Sealing: PVC is the most forgiving with regards to heat sealing. As a result, machine efficiency increases and throughput is often better than PET. PVC works with just about every type of seal coating, including aqueous-based and solvent-based.

Excellent for RF sealing.
Min/Max Gauge: .010 – .045

Other PVC materials:

rPVC – Recycled PVC

VPVC – Virgin PVC

ESD PVC – Electro Static Dissipative PVC

FDA PVC – Food-grade PVC

PET or PETE (Polyethylene Terephthalate) may also be referred to as polyester. PET has excellent strength, toughness, dimensional stability, clarity, and abrasion resistance. PET is fast becoming a preferred material due to its ease of recyclability and extensive use in the food and beverage industry. PET can be identified by the #1 recycle symbol.

Heat Sealing: PET seals best with solvent-based coatings and select aqueous-based coatings.

Min/Max Gauge: .010 – .045

Other PET materials:

rPET – Recycled PET

APET – Amorphous PET aka FDA PET

FDA PET – Food-grade PET

PETG (Polyethylene Terephthalate Glycol) is similar to PET in properties and is known for its toughness, clarity, versatility, and ease to work with. The Glycol modified form of PET gives the material better impact resistance and is often used for medical applications requiring sterilization by EtO and Gamma rays. PETG can be used as an alternative to PVC when RF-sealing is required. PETG is also identified by the #1 recycle symbol.blister with cut-out

Heat Sealing: PETG is similar to PET with the forgiveness of PVC, and therefore works with a wider range of adhesives than PET.
Min/Max Gauge: .010 – .045

Other PETG materials:

rPETG – Recycled PETG

VPETG – Virgin PETG aka medical grade PETG

HIPS (High Impact Polystyrene) is a modified form of polystyrene where rubber molecules are added to give the material higher impact strength and better elongation. HIPS has a lower density than PVC and PET which results in more parts per pound when thermoformed. Typical thermoformed parts include trays, tubs, and clamshells, and it can be used when sterilization is required. HIPS is typically made to a specific PMS color but also comes in clear & natural (milky).  Utility grade Black and White HIPS are widely available and offer a low-cost material option.  HIPS has limited chemical resistance and has a tendency to crack when under stress.

PP (Polypropylene) is characterized by its excellent resistance to water, salt water, and acid solutions. PP has excellent toughness and fatigue endurance but becomes brittle at low temperatures. PP has the lowest density of the plastics used in packaging, which has contributed significantly to its growing popularity. Typical applications include food trays, clamshells, and protective packaging. HDPE is identified by the #5 recycle symbol.

Min/Max Gauge: .010 – .050

Co-Polymer PP, available in natural, white, black, or color match
Homo-polymer PP, available in natural, white, black, or color match