Food Blister Packaging.

Use PET or food-grade RPET for chilled and ambient foods, and PP if the pack goes in a microwave. PET gives the clearest view of the food but softens with heat. PP holds its shape at reheating temperatures, which is why sauce pots and ready-meal cavities are usually PP.

Tell us the temperature the pack will see in use and we'll choose a sheet rated for it.

A peelable lid lifts off the flange in one piece, while a push-through lid is a foil the food is pressed through from the cavity side. Peel lids suit dips, sauces and snacks eaten straight from the tray. Push-through suits small solid pieces like mints or gum.

The lidding is tuned to the tray sheet so the seal holds through distribution and still opens by hand.

Yes, we form compartmented trays with a separate cavity for each item, the format behind most snack and protein boxes. Every cavity seals under the same lid, so wet and dry foods stay apart until the pack is opened. The cavity volume also fixes the portion, which keeps servings consistent.

Deeper compartments may need a heavier gauge so the walls don't thin out during forming.

Shelf life depends on the barrier of the tray and lid, so we choose the film to suit the date you're targeting. Standard PET works for short chilled life. Barrier laminates slow oxygen and moisture through the walls, and trays can be sealed under modified atmosphere where your line supports it.

Fibre-formed cavities are an option for brands moving off plastic, though their barrier differs, so we'd confirm them against your target date.

Branding goes on the printed backing card or lid, and the food in the clear cavity does most of the selling. We print the card in CMYK and can add spot UV to pick out a logo, while the cavity face stays free of graphics. The card also has room for the nutrition panel.

Leave a clean zone for date and lot codes, which are applied on the packing line.

We size each cavity from the portion it holds, by volume or by the dimensions of the piece, then add a small clearance so the lid seals flat. An overfilled cavity pushes food onto the flange, and that stops the lid sealing properly.

For multi-cavity trays we work from the overall footprint your sealer takes and divide the compartments inside it.

Food blister orders start at 500 units. We run up to 100,000 on a single order, so a pilot batch and a full retail launch can come off the same tooling.

Every sheet and lidding film we use in the order is food-contact grade, whatever the quantity.

Plan on 7 to 10 business days for production after sign-off, or 5 to 7 on a rush. Formed and sealed samples come in 5 to 7 business days so you can run them through your own filling and sealing setup. The fee for samples is deducted from the bulk order.