Blister Packaging
Engineered Blister Packaging That Protects, Promotes & Performs
Blister packaging is more than just a protective shell — it’s your product’s first impression on retail shelves and your defense against damage, theft, and contamination. At Algus Packaging, we specialize in designing and manufacturing custom blister packaging that helps brands stand out while ensuring the highest levels of product protection.
With over 20 years of experience serving leading manufacturers across industries, Algus provides blister packaging that’s custom-fit to your products, your brand, and your supply chain.
What is Blister Packaging?
Blister packaging is a type of thermoformed plastic packaging commonly used to secure and display consumer goods. It typically consists of a clear plastic cavity (the “blister”) that holds the product and is sealed to a backing material such as a printed blister card or another piece of plastic.
Blister packs are widely used because they:
- Protect products from tampering and environmental damage
- Allow for clear product visibility and shelf appeal
- Provide branding space via printed backing cards
- Are cost-effective for both low- and high-volume production runs
From face-seal blisters to trapped blisters and full clamshells, Algus designs packaging that meets both aesthetic and functional requirements for a wide range of industries.
To learn more about our blister packaging capabilities, connect with Algus Packaging now by calling 815-281-5297.
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Types of Blister Packaging We Manufacture
Algus manufactures a variety of blister packaging formats to meet the unique demands of different products and industries:
Face Seal Blisters
The most common form of blister packaging, where the blister is sealed directly to a printed card. Ideal for lightweight products requiring high product visibility and strong branding.
Trapped Blisters
The blister is sandwiched between two cards, locking the product in place while providing extra space for marketing and instructions.
Full Clamshells
A hinged two-part blister design that fully encloses the product, often with snap closures or heat-sealed edges for added security.
Custom-Formed Blisters
We create tailor-made blister cavities for irregular or complex product shapes to ensure secure placement and minimize product movement.
Industries We Serve with Blister Packaging
Algus blister packaging is trusted across a range of industries where product protection and shelf appeal are critical:
Consumer Electronics: Secure packaging for cables, headphones, accessories, and devices.
Health & Beauty: Display-friendly blister packs for cosmetics, razors, toothbrushes, and personal care products.
Pharmaceutical & Medical Devices: Blister packaging for OTC drugs, diagnostic kits, and sterile medical devices.
Toys & Sporting Goods: Tamper-resistant packaging that showcases the product clearly and withstands handling.
Hardware & Tools: Rugged blister packs designed to protect sharp or heavy components during shipping and retail display.
Benefits of Custom Blister Packaging
When it comes to blister packaging, there’s no such thing as one-size-fits-all. Every product has unique protection and presentation needs — and Algus designs blister packaging to meet them all.
Enhanced Product Protection
Our thermoformed blisters safeguard products against impact, moisture, dust, and tampering throughout the entire distribution cycle.
Brand Visibility & Consumer Appeal
Custom-formed blisters combined with high-quality printed cards help your product grab attention on crowded shelves. The clear plastic also provides full product visibility, building consumer trust.
Tamper-Resistance & Theft Deterrence
Blister packaging is often used to deter theft and unauthorized opening at retail thanks to its secure heat-seal process and durable materials.
Sustainability Options
Algus offers eco-friendly blister packaging using recycled and recyclable materials, including RPET and PETG, helping your brand meet its sustainability goals.
Cost-Effective Packaging
Blister packaging is efficient to produce at scale, providing a lower cost-per-unit while offering excellent product protection and brand exposure.
Custom Blister Packaging: Designed & Manufactured In-House
What sets Algus apart from standard packaging suppliers is our ability to design, prototype, and manufacture custom blister packaging entirely in-house. We don’t rely on generic molds or templates. Every project starts with your product, your brand, and your packaging challenges.
Our in-house capabilities include:
- Thermoforming & die-cutting
- Rapid prototyping for speed to market
- Custom tooling designed to match your product’s exact dimensions
- Material consultation to help select the right substrate for durability, sustainability, and aesthetics
Need to quickly go from concept to shelf? Algus’ streamlined production processes ensure faster lead times and superior quality control — all under one roof.
Blister Packaging + Automation = End-to-End Efficiency
Many suppliers stop at just manufacturing packaging. Algus goes further by also offering custom blister seal machines, engineered to work seamlessly with the packaging we create.
This unique dual capability allows us to:
- Ensure perfect compatibility between packaging and sealing equipment
- Speed up project ramp-up times with faster prototyping and testing
- Offer automation-ready packaging for integration into high-speed packaging lines
When you work with Algus, you’re partnering with an expert in both packaging production and automation design, eliminating the inefficiencies that come with juggling multiple vendors.
Why Choose Algus for Blister Packaging?
When it comes to blister packaging, selecting the right partner can make all the difference in product protection, presentation, and production efficiency. Algus stands out as a trusted leader in the industry, combining decades of expertise with a commitment to innovation and client success. From specialized packaging solutions to full-scale automation, Algus brings unmatched capabilities to every project.
Here are just a few reasons why companies consistently turn to Algus for their blister packaging solutions:
- 20+ years of experience in blister packaging and sealing automation
- U.S.-based manufacturing with complete in-house design and tooling
- Experts in custom-shaped packaging for products that don’t fit stock solutions
- Proven track record serving global brands across consumer goods, medical, and industrial sectors
- A collaborative team dedicated to solving complex packaging and production challenges quickly
Take the Next Step with Algus Packaging
Whether you’re launching a new product, switching to more secure packaging, or optimizing for automation, Algus Packaging is your trusted partner for custom blister packaging that performs.
Contact us today at 815-281-5297 to discuss your project and learn how we can help you protect and present your products more effectively.