Custom Blister Boxes & Blister Packaging
A blister box is what happens when you want the visibility of a blister pack with the structure of a carton. The formed shell holds the product, and the printed box gives you panels for branding, compliance copy and a proper shelf presence. It suits products where a bare card looks too flimsy. We produce a lot of blister packaging at ZEE Packaging and combining the two formats well is the actual skill here.
Structure Plus Visibility
A blister box gives you both things at once.
- The formed shell keeps the product visible and secured
- The carton adds panels for branding and information
- It stands upright on a shelf rather than hanging only
- The board hides the seal flange, which looks tidier
- Tamper evidence comes built into the sealed shell
- It reads as a considered product rather than a bagged one
Most brands moving to a blister box do so because a plain card was not carrying enough information.
The Shell And The Board Must Agree
Getting these two working together is where projects go wrong.
- The window must line up exactly with the formed shell
- Seal flange dimensions dictate the board area needed
- Heat sealable coating has to cover the full flange
- The board must be stiff enough to stop the seal flexing
- Any internal ribs on the shell need clearing at dieline stage
- We work from the actual tooling rather than a drawing
- Window carton with a sealed shell the standard blister box
- Face seal onto an inner card the shell sealed to a panel
- Trapped blister sandwiched between two board layers
- Clamshell inside a sleeve a lower cost combination
- With a euro hole for peg display alongside shelf standing
- Two piece carton and tray where a shell is not required
Sizes We Print Regular
Every blister box is built to your tooling, though these run often:
- 4" x 6" x 1" for small tools and accessories
- 5" x 8" x 1.5" for mid size products
- 3" x 5" x 1" for compact goods
- 6" x 9" x 2" for larger items
- 7" x 10" x 1.5" for bulkier products
- Custom sizes matched to your existing shell
Send us the shell itself, since flange width determines the whole carton footprint.
Board And Print
- 20pt to 28pt card stock depending on product weight
- Heat sealable coating across the seal area
- White SBS for vivid retail print
- Kraft board where a natural position suits the brand
- Matte lamination outside the seal area only
- One or two color flexo for high volume runs
Board stiffness is worth spending on. A flexing blister box breaks its own seal, and retailers notice that failure before the customer does.
- Paperboard tray instead of a formed shell where weight allows
- Recycled board across most grades we run
- FSC certified stock, certificate available on request
- Soy based ink through the whole run
- Compostable window film as a PET alternative
- Right sizing so no board or film is wasted
Where the product is light enough, a window carton with a board tray does the same job with a fraction of the plastic. We would raise that honestly rather than default to a shell.
What Ordering Involves With Us
- 100 unit minimum, so a small brand can order properly
- Free 3D mockup and flat proof before anything prints
- Free dieline drawn by our own designer
- Physical sample on request to test the seal
- Urgent turnaround at 5 to 8 business days
- Free shipping worldwide with nothing hidden
Frequently Asked Questions
Do you supply the shell too?
We print the board and can arrange forming and sealing alongside it, so everything comes from one supplier.
Why do seals fail?
Usually a missing heat sealable coating or a board too thin and flexing. Both are avoidable at specification stage.
How much is a blister box?
Rough estimate is $0.25 to $0.70 per unit for a printed carton, $0.45 to $1.20 with a sealed shell and $0.80 to $2.00 for larger formats at moderate quantity. Volume moves it. Shipping is included in our price. This is estimate only, so ask our team for a exact quote.
Which caliper should we use?
20pt for light items, 28pt for anything with weight. A sagging board stresses the seal continuously.
Can it hang and stand?
Yes, with a reinforced euro hole plus a flat base. Plenty of retailers use both display methods.
Can we avoid plastic entirely?
For lighter products, often. A window carton with a board tray achieves the same visibility with far less film.
Is it tamper evident?
Inherently, since opening a sealed shell leaves visible damage. That is one reason retailers ask for the format.
