Thermoformed Packaging Solutions: Blister, Clamshell & Tray Packaging
At Algus Packaging, we specialize in high-quality thermoform packaging solutions designed to meet the diverse needs of industries ranging from retail to medical. Whether you’re looking for durable blister packaging, secure clamshells, or custom tray and insert packaging, our thermoforming expertise ensures your products are protected, presented beautifully, and packaged efficiently.
Our thermoform packaging solutions are supported by advanced seal machines, including shuttle, rotary, and carousel systems, engineered for precision, flexibility, and high-volume production. Whether you need custom packaging or the machines to create it, Algus has you covered.
To learn more about the thermoformed packaging solutions available through Algus Packaging, please call our team today at 815-281-5297. You can also get in touch with any of our knowledgeable professionals electronically by completing the easy-to-use form featured on this page.
What is Thermoform Packaging?
Thermoform packaging involves heating plastic sheets until they become pliable, then molding them into specific shapes using custom-designed tooling. This process creates durable, lightweight, and cost-effective packaging solutions ideal for a variety of products.
At Algus, we provide:
- Custom Thermoformed Blister Packs
- Clamshell Packaging Solutions
- Tray and Insert Packaging for product protection and organization
Our thermoforming process is designed to deliver consistent quality, whether you’re packaging small medical devices or large consumer products.
Have a Question?
Contact us today for a clear solution to all your heat seal and thermoforming needs, or simply complete the below form.
Blister Packaging: Secure, Versatile, and Customizable
Blister packaging is one of the most popular thermoform packaging options, offering product visibility, security, and tamper resistance. Algus specializes in designing and manufacturing custom blister packs for retail, pharmaceutical, and medical applications.
Key Features of Algus Blister Packaging:
- Clear Product Display: Enhances shelf appeal with high-clarity materials
- Tamper-Evident Seals: Provides security for retail and medical products
- Custom Shapes & Sizes: Tailored to fit any product perfectly
- Material Options: PET, PVC, RPET, and eco-friendly alternatives
Types of Blister Packaging We Offer:
- Face-Seal Blisters: Sealed directly to a backing card
- Full Card Blisters: Encases the product between two cards
- Trapped Blisters: Secured between layers of printed cards for added protection
- Medical Blister Packs: Designed to maintain sterility and meet regulatory requirements
Supported by Advanced Seal Machines:
Our Universal 8 (U8) Rotary Seal Machines and Shuttle Seal Machines provide precise heat and pressure control, ensuring consistent, high-quality seals for blister packs.
Applications:
- Consumer electronics
- Pharmaceuticals
- Toys and household goods
- Medical devices
Clamshell Packaging: Durable Protection with Enhanced Visibility
Clamshell packaging offers a robust, tamper-resistant solution with clear visibility of the product. Made from a single piece of thermoformed plastic, clamshells are designed to fold over and snap shut or seal securely with heat.
Benefits of Algus Clamshell Packaging:
- Reclosable or Permanent Seals: Depending on your product’s needs
- Strong Product Protection: Impact-resistant design for heavy or fragile items
- Eco-Friendly Options: Recyclable materials available for sustainability goals
- Custom Design: Tailored fit for products with unique shapes
Types of Clamshell Packaging We Produce:
- Hinged Clamshells: For easy opening and resealing
- Tri-Fold Clamshells: Ideal for freestanding retail displays
- Double-Sided Clamshells: Provides maximum protection for high-value products
Seal Machine Integration:
Our Carousel Seal Machines are perfect for high-volume clamshell sealing operations, providing efficiency without compromising quality.
Applications:
- Hardware tools
- Cosmetics and beauty products
- Electronics
Tray and Insert Packaging: Organized, Secure, and Custom-Fit
While blister and clamshell packaging take the spotlight, tray and insert packaging plays a critical role in product protection and organization. Algus designs custom thermoformed trays and inserts that keep products secure during shipping, handling, and display.
Features of Algus Tray and Insert Packaging:
- Custom Cavities: Designed to fit products snugly, reducing movement
- Protective Design: Prevents damage during transportation
- Stackable Options: Optimizes storage and shipping efficiency
- Material Versatility: Available in rigid and flexible plastics for various applications
Common Uses:
- Medical device trays
- Automotive parts packaging
- Electronics inserts
- Cosmetic product trays
Our Shuttle and Rotary Seal Machines can be customized to handle tray sealing applications, especially for medical-grade packaging that requires validated sealing processes.
How Algus Seal Machines Enhance Thermoform Packaging
Algus doesn’t just produce thermoform packaging—we design and manufacture the machines that make the packaging. Our seal machines are engineered for efficiency, flexibility, and precision, making them ideal for thermoforming operations of all scales.
Shuttle Seal Machines
Perfect for short runs and custom packaging projects, shuttle machines offer:
- Precise Heat & Pressure Control
- Compact Footprint for Small Spaces
- Quick Tooling Changeovers
Universal 8 Rotary Seal Machines
For high-volume production, our U8 system provides:
- Modular Design for Flexibility
- High-Speed Sealing Capabilities
- Servo-Controlled Accuracy
Carousel Seal Machines
Ideal for large-scale operations with diverse product lines:
- Multi-Station Sealing for Efficiency
- Customizable Tooling for Different Package Types
- Continuous Motion for High Throughput
Whether you need custom thermoform packaging or the machinery to produce it, Algus offers complete solutions tailored to your business.
Introducing Algus-Eco: A Sustainable Packaging Solution
Algus Packaging is committed to innovation and sustainability. As part of our ongoing efforts to provide eco-friendly alternatives, we are proud to introduce Algus-Eco, a revolutionary bio-based thermoforming material that combines sustainability with the performance of traditional plastics.
Why Choose Algus-Eco?
- 72% Bio-Based Content – USDA-certified material derived from renewable resources.
- Industrial Compostability – Breaks down into CO2, water, and biomass, reducing plastic waste.
- Recyclable by Design – Proven recyclability through independent third-party testing.
- Seamless Integration – Runs on existing thermoforming and Algus sealing equipment.
- PFAS-Free and Non-Toxic – Meets strict safety standards, free from hazardous substances.
- Cost-Effective & Scalable – A viable alternative to traditional plastic and paper-based packaging.
Sustainability Without Compromise
With Algus-Eco, brands no longer have to choose between performance and environmental responsibility. This innovative material maintains the clarity, durability, and customization of traditional thermoformed packaging while significantly reducing environmental impact.
As the industry shifts towards sustainable solutions, Algus-Eco empowers businesses to meet their eco-friendly goals without sacrificing quality or efficiency. Our bio-based material seamlessly integrates with our high-speed thermoforming and sealing equipment, making it an easy transition for companies looking to adopt sustainable packaging.
Custom Thermoforming Solutions Tailored to Your Needs
At Algus, we know that every product is unique. That’s why we offer fully custom thermoforming solutions, from the initial design to final production. Our team will work closely with you to develop packaging that:
- Protects Your Product: Durable materials and secure seals
- Enhances Shelf Appeal: Clear, attractive displays
- Meets Regulatory Requirements: Especially for medical-grade packaging
- Improves Efficiency: Optimized for automated filling and sealing processes
Industries We Serve
- Retail: Consumer goods, electronics, cosmetics, toys
- Medical: Sterile medical devices, diagnostic kits, pharmaceutical packaging
- Industrial: Automotive components, hardware, tools
Why Choose Algus for Thermoform Packaging?
Complete In-House Capabilities
We handle everything from design and prototyping to production and machine manufacturing.
Customization & Flexibility
Whether you need unique blister shapes, secure clamshells, or specialized trays, we can create it.
Advanced Machinery Integration
Our seal machines are designed to work seamlessly with our thermoforming processes, ensuring consistent quality and efficiency.
Industry Expertise
With decades of experience in both packaging and machinery manufacturing, Algus is your one-stop partner for thermoform packaging solutions.
Get Started with Custom Thermoformed Packaging
Ready to elevate your product packaging? Call Algus Packaging today at 815-281-5297 to discuss your custom thermoformed packaging needs. Whether you’re interested in blister packaging, clamshell packaging, or custom trays and inserts, our team is here to help you find the perfect solution.