People usually arrive at packaging decisions late. Most manufacturers don’t start with packaging. They start with a product. Packaging only becomes a priority when something breaks. A shipment gets rejected. Retailers complain about theft. Products look fine in cartons but fall apart once they hit the shelf. Lead times stretch longer than expected. Suddenly, packaging is no longer a background task. It becomes the problem.
Powerpak Industries exists because we’ve seen this cycle repeat for decades.
We work with manufacturers who need blister packaging, blister pack packaging, and blister packaging machines that behave predictably once production ramps up and real-world handling begins. Not just during design reviews. Not just on the first order. But across repeat production, shipping, stocking, and retail exposure.
Retail packaging influences far more than appearance. It affects theft, compliance, shelf efficiency, and even how buyers judge product quality before touching it. According to the National Retail Security Survey from the National Retail Federation, retail shrinkage in the United States now exceeds 112 billion dollars annually. Theft and tampering remain major contributors. What is rarely discussed is how often packaging design makes theft easier or harder.
When products are easy to remove, they get removed. When seals weaken, people test them. When packaging hides the product, customers hesitate. When lead times stretch, launches slip. These failures do not show up in spreadsheets early on. They appear once the product leaves the building.
Our approach to blister pack development starts with how packaging behaves in stores, not how it looks in presentations.
See How we WORK in Blister Packaging
Blister Packaging Manufactures
The Original & Affordable
2-in-1 Blister/Clamshell Packaging Machine
- 4 - Station (Manual Rotary Table)
- Self - Indexing Guide
- Accommodates Blister Packs & Clamshell Packs
- 1-3 Person Operation
- Virtually Maintenance Free
- Runs Quietly & Economically
Affordable Retail Packaging
Whether you’re looking for blisters, cards, or clamshells, POWERPAK has got you covered!
- Clear visibility for product display
- Tamper-proof seals for added security
- Customizable shapes and sizes
- High-quality, durable materials
POWERPAK’s Blister packs and Blister Cards are made with only the highest quality materials. All cards and blisters are 100% consumer recyclable.
Standard blister packs use thermoformed plastic sealed to paperboard or foil. This format remains widely used because it balances cost, clarity, and protection. It works well for small to mid-sized items where customers need visibility and retailers need consistency.
Manufacturers often choose this format when they need space for instructions, compliance labeling, barcodes, and branding without overengineering the package.
Blister card packaging combines a printed card with a sealed plastic cavity. The card does more than display graphics. It affects hanging behavior, shelf spacing, and retailer acceptance.
We design card size, hang hole placement, and seal strength based on how the package will actually be stocked. This matters when products move across multiple retail chains with different fixture systems.
oldover packs fully enclose the product by folding plastic over itself and sealing the edges. Once sealed, access becomes obvious. This discourages casual tampering.
Manufacturers often select foldover packs for electronics, sharp items, or higher-value products where returns and theft are recurring concerns. The structure also improves durability during shipping and restocking.
Clamshell packaging uses two rigid plastic halves connected by a hinge. When sealed, the enclosure resists crushing and forced opening.
Retailers frequently prefer clamshells in high-traffic areas. Manufacturers choose them when protection and security outweigh concerns about material usage.
Fold seal packaging uses a single plastic sheet folded around the product and sealed at the edges. This approach reduces material usage and speeds assembly. It works best for lightweight items with lower theft risk where production speed and clean presentation matter more than heavy-duty protection.
Trapped blisters hold products between two cards. Slide blisters secure the card inside the plastic cavity. Both formats make removal difficult without visible damage.
Manufacturers often choose these formats for small, high-value products sold in open retail environments.
Hardware and Tools
Hardware products face constant handling and theft risk. Blister packaging secures items while allowing customers to inspect size and finish. Our designs support heavier weights and repeated handling without seal failure.
Electronics and Accessories
Electronics require protection without hiding the product. Blister pack packaging shields components from dust and handling damage while limiting unauthorized access. Proper cavity design reduces movement during shipping.
Health, Beauty, and Cosmetics
Presentation influences buying decisions. Blister packaging supports clean display while protecting products from contamination. Card design carries instructions, ingredients, and compliance information clearly.
Automotive Parts and Accessories
Automotive parts often have irregular shapes and added weight. Blister pack formats protect parts from abrasion and moisture while supporting consistent hanging across stores.
Sporting Goods and Outdoor Equipment
Outdoor products often include sharp edges. Blister packaging secures items safely while remaining visible. Our designs hold up through shipping and seasonal retail cycles.
Household and Consumer Products
Household products move quickly through retail. Blister pack packaging supports fast restocking, clear labeling, and theft deterrence without constant redesign.
Outsourcing packaging works until volume increases or schedules tighten. Missed deadlines become expensive. Quality becomes inconsistent. Small changes require long approval cycles.
Owning a blister packaging machine puts control back on the production floor.
Powerpak Industries builds machines that support blister pack, clamshell, and fold seal formats. These machines are designed for manufacturing environments, not showrooms. They run quietly, require minimal maintenance, and integrate into existing workflows.
Manufacturers use our blister packaging machine systems to reduce dependence on third parties, protect product designs, and adjust schedules without waiting.
Outsourcing packaging works until volume increases or schedules tighten. Missed deadlines become expensive. Quality becomes inconsistent. Small changes require long approval cycles.
Owning a blister packaging machine puts control back on the production floor.
Powerpak Industries builds machines that support blister pack, clamshell, and fold seal formats. These machines are designed for manufacturing environments, not showrooms. They run quietly, require minimal maintenance, and integrate into existing workflows.
Manufacturers use our blister packaging machine systems to reduce dependence on third parties, protect product designs, and adjust schedules without waiting.
A blister pack uses a molded plastic cavity that holds a product in place and seals to a backing card or foil. The product stays visible. That visibility matters. Customers want to see what they are buying. Retailers want to reduce returns.
But blister packaging is not just plastic and paperboard. The cavity shape controls movement during shipping. The card stock controls hang strength. The seal method controls theft resistance. The display orientation controls how the product sits on a wall.
A functional blister packaging solution balances all of these details together. That is why blister packing continues to be used across categories where protection and visibility must coexist.
Other PRODUCTS THAT WE PROVIDE
Blister Packaging Machinery By POWERPAK
The Original 4 Station Blister Clamshell Sealer
The Original Flip Sealer Blister Packaging Machine
The Original 4 Station Blister Clamshell Sealer Clean Room Model
2 Station Blister Clamshell Sealer Club Pack Model
Blister Packs
Clamshell Packaging
Foldover Packs
Fold-Seal™ Packaging
Folding Cartons
We built our process around clarity, speed, and accountability.
Step 1: Project Evaluation
We start by reviewing the product, its use environment, retail destination, and production goals. This step prevents design issues later and ensures the packaging matches real-world conditions.
Step 2: Design and Engineering
Our team creates CAD designs that account for product tolerances, seal strength, and display orientation. We also review card layout, hang hole placement, and material thickness at this stage.
Step 3: Prototyping and Testing
We produce prototypes to test fit, stability, and handling. Manufacturers review samples and request adjustments before committing to production tooling.
Step 4: Tool Development
Once approved, we develop tooling with shorter lead times than most competitors. This stage focuses on repeatability and long-term production efficiency.
Step 5: Production and Fulfillment
We schedule production quickly after approval. Packaging ships ready for retail or internal assembly based on customer needs.
Step 6: Repeat Orders and Scaling
Repeat orders move faster with established tooling. We also support inventory programs for high-volume manufacturers to reduce downtime.
Why Manufacturers Continue Working With Powerpak Industries
- One source for machines, tooling, and supplies reduces friction.
- Shorter production cycles reduce launch delays.
- Lifetime machine warranties protect long-term investments.
- US-based support improves response time.
- Experience comes from solving real packaging failures.
- Systems scale instead of breaking under growth.
- If packaging slows sales, increases shrink, or delays launches, the issue is rarely the product. It is the packaging system.
Powerpak Industries builds blister pack packaging systems that stay reliable under pressure.
What Actually Makes Us Different?
- Packaging designs that make tampering obvious, not subtle
- Tooling timelines that do not stall product launches
- In-house blister packaging machine options for companies tired of outsourcing delays
- Packaging formats already accepted by large retail chains
- Materials chosen for how they behave during handling, not just how they test on paper
More than 500 brands continue to work with us because the packaging holds up after repeated production runs.
WHY BRANDS LOVE US
Retail Product Packager
Powerpak Industries is an exceptional company that I have had the pleasure of working with. Their dedication to providing the best blister packaging solutions is truly remarkable and has made them a top choice in the industry. I have had the pleasure of working closely with Bob and Melody, the dynamic duo behind Powerpak Industries, and I can confidently say that their passion for their work is unmatched. They are always willing to go above and beyond to ensure that their clients receive the best service possible. From the initial design stage to the final product, Bob and Melody are involved in every step of the packaging process, ensuring that every detail meets their high standards. Their attention to detail and commitment to quality is evident in the final blister packaging product, which is always top-notch. Working with Powerpak Industries has been a true pleasure, as their team is not only knowledgeable and professional but also friendly and approachable. They truly listen to their clients’ needs and work tirelessly to provide the best solutions for their packaging needs. It is no surprise that they have a loyal customer base, as they consistently deliver exceptional results. I highly recommend Powerpak for anyone looking for the best blister pack machine solutions and an outstanding customer experience. Bob and Melody’s dedication to their work and their clients is truly admirable, and I am grateful to have had the opportunity to work with such an amazing blister packaging company.
Retail Product Packager
I have been working with Powerpak for ~5 years for our blister machine packaging needs. They have been very helpful selecting the right blister pack machine products for our business needs and have always been available if we had questions or needed help with our blister machine equipment. During a recent move from CA to NV, they also recalibrated our equipment and crated it for safe transport. Most recently we started a conversion from blister to enviro-friendly plastic free blister packaging which required several design iterations to capture the essence of a secure product in enviro-friendly packaging, but Powerpak was patient with our changes and went full throttle when it was time to print. As a small business, we love supporting other small businesses and are grateful to have Powerpak as our packaging partner.
Retail Product Packager
Finding the Powerpak Blister Machine for our small business was the best thing that could’ve ever happened to our brand. We were able to accept an order for over 100,000 units and save over $20,000 by not having to pay a contract manufacturer to manage the job for us. This machine alone has significantly improved our blister packing machine capabilities and allows us to continue to grow our business due to the speed in which it completes our blister packaging machine. Not to mention, the customer service that Bob and Melody provide is unmatched. We are grateful for our relationship with Powerpak.
Retail Product Packager
Throughout our 13-year partnership, Powerpak has exhibited exceptional service and dedication to our company. The quality of the products/services provided has been exemplary, consistently meeting and often surpassing our expectations. Powerpak has always accommodated and valued our business needs, and more importantly our relationship. Powerpak’s promptness in addressing our requirements, coupled with their reliability in meeting delivery deadlines, has greatly contributed to our operational efficiency. Thank you once again for your outstanding blister packaging service and collaboration to our company’s success. We value our partnership and look forward to continued growth together.
Retail Product Packager
I have been working with Powerpak since the week I went into business 27 years ago. Someone recommended them to me and I have been a customer ever since. I cannot say enough about their integrity and how I was treated right from the beginning. They make the best blister machine packaging and take care of their customers 100%. Look no further if you are looking for a terrific team to work with.
Retail Product Packager
I have been doing business with PowerPak Industries for about two years, and I have consistently received outstanding blister packaging customer service. Despite the small size of my company, which initially provided limited business for them, the PowerPak team exceeded expectations in accommodating my needs. I am extremely pleased with our business relationship and eagerly anticipate many more years of successful business growth, with complete confidence in our packaging!
Retail Product Packager
We have been working with Powerpak for quite a few years now and they have been nothing short of amazing! Their blister packaging machinery products have always been high quality and the customer service is exceptional. Highly recommend.
Cherub Marketing, inc.
Cherub Marketing has been using PowerPak for over 25 years. We sell products to the U.S. military—it has to be perfect every time.Thank you, PowerPak, and thank you to the PowerPak team.
You’re the best.Cherub marketing,inc. 10436 artesian springs ct
Our Story
When it comes to blister packaging, we may know a thing or two.
Thanks to the late Peter Green. Proud dad of now CEO, Bob Green.
He not only left behind a charming smile, a witty sense of humor, and a loving family… but something important Powerpak incorporates into our business practices today: INTEGRITY.
It all started when Peter Green owned a company “Century Printing LTD.” He was approached by Aaron Fish, CEO of “ILCO UNICAN” who had a hardware line. He complained that their products were being stolen out of bins. Peter took some samples and saw his good friend and thermoforner, John Fisher. John mostly formed chocolate trays, but Peter asked him to try to form clear plastic over ILCO Unican’s products.
After successfully doing so, he printed the cards, created the machine, sealed the packs and the rest remains history!
FAQS.
What is a blister pack?
What is blister packaging used for?
How do I choose the right blister pack for my product?
When should manufacturers use blister packaging instead of boxes or pouches?
What products work best with blister pack packaging?
When should I use blister card packaging for retail sales?
Is blister packing suitable for high-volume manufacturing?
When does it make sense to use a blister packaging machine in-house?
Blister packaging, is a durable and customizable solution featuring a clear plastic cavity sealed to a backing, ideal for protecting and displaying products like retail goods, electronics, and cosmetics.
Blister packaging comes in several forms, including:
- Front face Seal Blisters: Clear plastic sealed to a flat backing.
- Full Blister Cards: Fully encloses the product with a durable seal.
- Clamshells: Hinged designs that open and close.
- Pharmaceutical Blisters: Individual compartments for pills or tablets.
These forms can be customized to fit specific product needs.
If you have a new product you believe is ideal for retail, we are here to assist you. Contact our team, and one of our experts will provide dedicated guidance and resources to help you take the next steps. We may request product samples to be sent to our main location, enabling us to create a mockup design to ensure we’re aligned with your vision. Additionally, we’ll collaborate with you to determine the most suitable packaging options, tailored to your product, budget, and volume requirements.
We work in CMYK format and our preferred format for artwork is Adobe Illustrator (Ai). Within the art files, all fonts should be converted to outlines and any linked images should be imbedded. Text and graphics should be at least .125″ away from any cut and or trim areas, to allow for cut tolerance. The file should have a .125″ bleed beyond the die line. Corners of the card should have a radius (recommended .25″) because square corners tend to dog ear. The hang hole should be placed at balance point. You will always receive a hard copy proof via mail to review and approve before production.
The Headquarters for Powerpak Industries LLC. is located in San Diego, California. They are a proud USA based company who serves companies all over the world.
Why do you offer a lifetime warranty on your equipment?
We offer a lifetime warranty on our equipment because we are confident in the quality, durability, and craftsmanship of our products. Our goal is to provide our customers with reliable solutions they can trust for years to come. This warranty is a testament to our commitment to customer satisfaction and our belief in the long-term value of our equipment.
We are family owned and operated and the originators of retail blister packaging since 1949. There are other options out there, but when it comes to knowledge, personalized experiences, and trust…we have your back. We believe customer service is key to success in any business and we value long lasting relationships with our customers
and their products.