Sealing issues in blister packaging can turn a well-designed product into a logistical headache, risking contamination, product damage, or even customer returns. Whether you’re working with custom blister packs, thermoformed trays, or plastic clamshells, a weak seal undermines both protection and brand trust.
Let’s break down the most common culprits behind sealing failures and how to fix them.
One of the primary causes is material incompatibility. When the blister (often made of PET, PVC, or PP) and the sealing layer (like cardboard or a heat-seal film) are made of mismatched materials, they may resist bonding.
For example, PVC blisters require a different heat-seal temperature than PET, and using the wrong film can result in partial seals or peeling.
The fix? Always verify that your blister material and sealing layer are designed to work together—reputable suppliers of custom blister packaging can recommend compatible pairs based on your product’s needs.
Temperature and pressure mismanagement is another frequent offender.
Heat-sealing equipment that runs too hot can melt the blister material, creating weak spots, while insufficient heat leaves gaps. Similarly, uneven pressure across the sealing area—often caused by worn equipment parts—leads to inconsistent bonds.
To resolve this, calibrate your machinery regularly: use a temperature probe to ensure precise heat settings (typically 160–200°C for most thermoplastics) and check that pressure plates are aligned and free of debris.
For high-volume runs, investing in automated sealing machines with digital controls can maintain steady parameters, reducing human error.
Worn or poorly maintained tools are also silent troublemakers. Dull or damaged sealing dies can create uneven contact, while misaligned molds may cause the blister and seal layer to sit unevenly before bonding.
Regularly inspecting and cleaning equipment—including replacing worn gaskets or resurfacing sealing plates—prevents these issues. Additionally, testing seals with pull tests or vacuum checks during production catches problems early, before defective blister packaging reaches customers.
Addressing sealing issues isn’t just about fixing mistakes—it’s about enhancing your product’s reliability.
By pairing quality materials, calibrated equipment, and proactive testing, you ensure that your blister packs, clamshells, or trays deliver the protection and professionalism your brand demands.
After all, a strong seal is more than a technical detail; it’s a promise to your customers that their purchase is safe and secure.
English
français
العربية
