Cost of Thermoform Packaging
Blister packs involve two types of materials: the backer cards that are paper based and the blister itself that is a thermoformed plastic container.
The thermoform is the deciding factor, where 1,000 units is extremely expensive, about $2-3 for just the thermoform tray. You may want to consider at least 5000 units to have a good price for a blister pack, and you’d still be looking at about $1.65. This is because this type of packaging also involves someone to insert your product before they seal the blister pack. So either the manufacturer of the blister packaging must do it or another company that does fulfilling and has blister pack machinery.
Cost of Blister (Thermoform Tray Only) |
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Volume Classification |
Volume (Units) |
Investment $ |
Tooling |
Prototypes |
1 – 10 |
$5 – $10 Each |
$600 |
Short Run |
50,000 – 100,000 |
$0.09 – $0.12 |
$4400 – $5500 |
Mid /Large Run |
100,000 – 500,000 |
$0.05 – $0.07 |
$4400 – $5500 |
Additional Thoughts
Besides the number of colors printed, materials, volume, and size of your packaging, another major factor that affects unit cost is the size of the machinery.
Smaller machines require smaller, less expensive tooling. Larger machines have larger tooling costs, however, these costs usually mean a smaller total unit cost because you can fit more units on a larger piece of tooling, if that makes sense. So a larger folding carton cutting die can cut out a greater number of boxes with each motion.
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