Call MSL COPACK + ECOMM @ (888) 675-4639 to discuss how we may successfully manage your project.

Consumers like to clearly see the product they’re buying. This is critical for product marketing, but product manufacturers and retailers shy away from the products being directly handled or tampered with by consumers in any way. The answer? Blister packaging.

MSL Specialized in medium to large volume runs for multiple formats of blister packaging.

  • Single face blister
  • Trap / folded card blister
  • Clamshell / hot cold process
  • Club Store large format (up to 18″ x 24″) with integrated club tray / POS display capabilities
  • Custom thermoform design
  • Multiple small to large format semi-automatic Starview and Visual 6 station rotary blister
  • Full Retail EDI integration / reorder / restock

Blister Packs: Twin Benefits for Product Retailing

Medication, cosmetics, electronics, hardware, toys, and nearly any other product category one can think of—all benefit from blister packaging. A blister package is how products can be retailed with the benefits of being visible to consumers, while also protecting the product from being directly handled.

At MSL, we do not expect our partners to be experts at blister package design. When a client lands mass orders from a big box retailer, club store, or online marketplace, MSL can step in and provide a full-service solution—from custom design, to production, to order fulfillment, and shipping. Call MSL at (888) 675-4639 to discuss your next blister packaging project.

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Blister Packaging Types, Materials, and Design

The blister packaging solutions we provide to MSL customers all involve sealing plastic to paperboard cards and the product(s). Here are some of the most common options:

The MSL Difference approach to secondary contract packaging & assembly excellence focuses on the following aspects:

Face Seal Blister:

Thermoformed plastic such as PVC contains the product and has flanges around it that are heat-sealed to the card, but not all the card is covered by plastic.

Full Face Seal Blister:

Same as above, except the entire front of the card will be covered with the plastic seal.

Full Card Blister:

Instead of being heat-sealed to the card, this type of blister has flanges that wrap around, meaning the card is inserted into the blister. This may require a mechanism to secure the card, such as a staple or locking flange.

Sustainable Plastic Alternative Environmental Blister Packaging:

With a special partnership with Pack 360, MSL is proud to offer a fully recyclable paper blister package containing zero plastic.Ask MSL how we may help your brands sustainable scorecard and environmental impact. 

Trapped Blister:

Instead of the blister being heat sealed to the front of a card, its flanges are instead trapped between two cards that adhered together. The front card is die-cut to accommodate the blister that protrudes through the card or front and back (double trap blister). The back card may include scored areas for ease of opening. Capable of up to 18” x 24” large club format blister sealing, MSL pairs this process with POS Display design for Club POS programs.


When products are encased in a plastic container with two halves hinged together for ease of opening and closing. These may or may not make use of a card in the design. Clamshell packaging, however, has largely fallen out of favor for most products due to environmental impact and concerns.

A large blister pack, for us, would be a card that ranges up to the 18”x24” size. A blister pack card can also be as small as a single lipstick, ranging all the way down to 1”x3”. Our blister packaging production runs range from 10,000 units up to one million + per run.

The paperboard card also represents a graphic design opportunity. These cards can be printed in order to convey product brand information and messaging, use instructions or other information both on the front and back as desired.

Blister Packaging

Retail Options for Blister Packed Products

Blister packaging needs to be designed correctly for different intended retail applications. In brick-and-mortar retail stores, the paperboard card typically has a peg hole in the top so it can hang on display racks. 

Blister packaging for club stores—Costco, Sam’s Club, and BJ’s Wholesale Club—tend to fall in their own category and format, including meeting specific requirements around seal tolerance.  Club format generally includes size specific folding trays to display product upright on a shelf or POS display.  MSL is deeply familiar with these different specifications to ensure blister packaging is the best fit; not only for the product, but also for the specific retail outlets where it’s sold.

The club store POS display format involves an overlap with assembly processes. This is a key example of where MSL differentiates itself from other providers who may do high-speed blister packaging, but do not have the additional POS display capabilities when club stores are the intended retail outlet.

MSL COPACK + ECOMM: Blister Packaging and Order Fulfillment Services

At MSL, we’ve made secondary packaging, kitting, bundling, and assembly the core of what we do. After all, you don’t need these key services to be an afterthought. There are third-party logistics service providers who may not offer the kinds of secondary packaging services your company needs. In other cases, they may provide limited “value-added services” for some types of secondary packaging, such as blister packaging, but charge a premium price for those services because they aren’t at the core of their service offerings. 

What “value-added” means when you work with MSL is that we also offer full warehousing, distribution, inventory management, and order fulfillment services to deliver your newly packaged items to wherever they need to go, whether that be large brick-and-mortar retail outlets (Target, Walmart, etc.), club stores (Sam’s, BJ’s, Costco, etc.), online marketplaces (Amazon, eBay, Wayfair, etc.), directly to consumers through eCommerce order fulfillment, or any combination of those retail types. When it’s time to plan your company’s next blister packaging project, call MSL at (888) 675-4639 to see how we can meet your needs and get a quote for our services.

For more information on the MSL Difference, Please contact MSL today to start the conversation by calling (888) 675-4639.