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PaperBlister™ FAQs

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Can I run PaperBlister™ packaging on non-Alloyd sealing equipment?

Though we believe Alloyd equipment is best suited for sealing PaperBlister™ packaging applications, we suggest you reach out to your machine supplier to ask if they can provide you with the necessary specifications. Sonoco Alloyd is unable to guarantee packaging on behalf of other equipment suppliers. 

Do PaperBlister packaging designs require longer lead times?

No! While more design work may be required for new projects,  PaperBlister packaging, itself, does not require longer lead times. In fact, lead times are frequently reduced because no Blister Form Tools are required for the design.

What are your standard lead times?

Lead times for PaperBlister packaging are the same as they are for traditional blister packaging, which are about 5-7 weeks.      

Is there a way to hold my product in the blister package to prevent it from rotating or shifting?

Yes, there are several possibilities depending on the product and package design. Glue dots, insert paper trays and embossing are all viable options to prevent rotation.

What is a typical cost for upgrading my existing Alloyd® machine to accommodate PaperBlister packaging designs?

Each machine is evaluated individually, but we estimate a range from $5,000 to $10,000 depending on the machine type and operational status.

What are the minimum and maximum depths a PaperBlister package can accommodate?

We recommend a minimum depth of ½ inch and maximum depth of 2 inches.

How fast can I run PaperBlister packaging on my existing Aergo® equipment?

We recommend 10-13 cycles per minute (CPM) as a maximum run time. Higher or lower run times may be achievable based on certain configurations.

Does PaperBlister packaging require more electrical or air supply usage on a machine?

No, the electrical and air usage is the same as standard plastic-to-card packaging.

How does the number up on a tray for paper-to-plastic sealing compare to PaperBlister packaging?

PaperBlister packaging generally reduces the number ‘up’ on a tray by one or two per seal tool layout because of the space needed to form the package from the card chute into the forming tray. This is determined on a case-by-case basis and our designers would be happy to develop configuration layouts to help you determine if PaperBlister packaging is right for your production floor.

Can I do my own conversion on my Alloyd® machine?

No, we do not recommend customers doing their own PaperBlister packaging conversions. Converting a machine without Alloyd® technical support voids the warranty and could possibly damage the equipment.

Can we put a foot on a PaperBlister package so it is able to stand?

We would be happy to work with you to develop the footed product you desire.

Is tooling changeover time longer for a PaperBlister packaging set of tooling?

No, PaperBlister tooling changeover takes the same amount of time as any other tooling changeover on your machine. 

Besides tooling changeout, do I need to do anything else to the machine to transition from  PaperBlister packaging to traditional plastic to card packaging?

No, after your PaperBlister packaging conversion kit is installed, it is permanent and there is nothing else you must do. There are no special procedures or items to remove; and beyond the tooling sets, no special procedures or items are required to go from PaperBlister packaging to traditional packaging.

Can I have printing on both sides of my PaperBlister packaging card? I’d like printing on the inside of the package.

Yes, double-sided printing is available with PaperBlister packaging. 

Am I saving money with PaperBlister packaging?

Average material costs are generally the same. With no Blister Tooling design and manufacturing costs, however, PaperBlister packaging saves you in initial fees and manufacturing run time.

Does tooling for PaperBlister packaging cost more than traditional face seal tooling?

There is a one-time slight increase over regular face seal tooling because there are more critical components addressing the alignment and force necessary to position and form the PaperBlister package.

Can post-consumer recycled board be used for this style of packaging?

Yes, all paperboard currently used for blister packaging can be used for PaperBlister packaging, including SFI certified board. (Please note: SFI requires an extra fee for certification.)

Can I have different shaped cut outs in the front and/or back of the PaperBlister package?

Yes, various custom cut sizes and shapes are available for windowing on the front and back of the PaperBlister package.

What types of products are best suited for PaperBlister packaging?

Many retail products currently in traditional blister packages, smaller club packages and windowed folding cartons are well-suited for converting to PaperBlister packaging. Contact us today to find out if PaperBlister packaging is right for your product! 

What are the main advantages of converting from face seal blister packaging to PaperBlister packaging?

  1. Offers a 100% recyclable, mono-material package with no capital investment in new equipment. 
  2. Meets increasing retailer sustainability requirements.
  3. Improves overall impression of environmental impact to shoppers.

What are the effects of humidity on a PaperBlister packaging machine and how does it affect the cards? Does humidity (low or high) effect how this package folds? 

  1. A moisture content range of 5%-7% is essential for maintaining paper of satisfactory strength and workability. This requires an indoor Relative Humidity (RH) of about 40%-50%, depending upon the composition of the paper.
  2. Humidity or lack thereof will influence the substrate. Too much and the board becomes flimsy and tends to roll rather than fold. Too little and the board will crack. 

What is the typical dwell time for PaperBlister packaging compared to traditional plastic-to-card blisters? 

Customers may expect a one-second reduction in dwell seal time compared to similar PET to SBS carded package styles. That means higher cycle speeds over traditional sealing parameters.

Do the card and PaperBlister package back both need to be heat seal coated or just one side?

For seal consistency, we recommend that both surfaces have applied adhesive coating. 

Where can I learn more?

PaperBlister Microsite

Learn even more with videos straight to your inbox, including short product videos and a full Q&A webinar with a PaperBlister technical expert.


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