One of our most frequent manufacturing projects, thanks in large part due to their diversity and wide range of potential uses across several industries, are blister packs.

Regardless of whether you need a crash course in why blister packs might be the best option for your needs or want to know what sets Janco’s process apart, you’ll find answers below.

Here’s what we’re covering:

• Types of Blister Packs
• Common Industry Uses
• Blister Pack Benefits
• Blister Pack Materials
• Janco’s Custom Thermoforming Process
• Why Janco?

Types of Blister Packs

Ever wonder why you’d go with a traditional blister pack VS clamshell packaging?

Trying to figure out what type of blister pack is the right fit for your needs depends on several variables, from the product you’re packaging to the quantity that you need to manufacture.

While there are a ton of similarities in terms of benefits, there are also some essential differences that make each type of blister pack ideal for specific product needs. Here’s a quick breakdown of what sets different models apart.

Clamshell: Most variations of blister packs use a cardboard backing, but a clamshell package is a bit different. Instead, two plastic pieces are hinged together in the thermoforming process, either at the side or at the base. This comes in handy in a variety of different ways, allowing clamshell packaging to stand upright on shelves when stocked in stores.

Our custom design process gives you the freedom to ensure the clamshell is aligned with your distinct needs, so the plastic may be heat-sealed closed on both ends or have a button to snap one side open and shut.

Most commonly, clamshells are used for sets that have more than one part, such as tool sets with several nuts and bolts or toy sets with multiple small parts. Generally, this type of packaging gives your product the same level of protection as any other blister packaging but works best for products that require more of a unique approach or need to be re-sealed after use.

Face Seal Blister Packs: This is what would be considered a traditional blister pack, where the plastic blister is designed and manufactured to fit your product (or several products) and then heat-sealed to a cardboard backing. This is ideal for packaging items made in large quantities because it’s fairly inexpensive compared to other options.

Trapped Blister Packs: This is the most similar to the traditional blister pack, but there are a few key differences. With a trapped blister, the name says it all – your plastic will be trapped between two pieces of cardboard. In addition to the usual cardboard backing, another piece is added over the front to cover the shape of your product using our custom die-cutting process. Because this doesn’t require blister pack heat-sealing methods, trapped blister packaging it’s generally a cheaper option.

Full-Face Seal Blister Packs: In another variation of the classic blister pack, the plastic surrounds both the product as well as the cardboard backing that supports it. Depending on your unique design needs, the plastic is heat-sealed to the card or slid through additional plastic pieces on each side. A full-face seal blister is typically used to enforce the strength of the blister pack packaging.

Full Card Blister Packs: Similar to a full-face seal blister, the plastic on a full card blister is manufactured to cover the entirety of the cardboard backing. Instead of using the typical heat-sealing process, this uses flanges that wrap around to seal the plastic.

Need help selecting the right type of blister pack for your packaging needs? We’ll provide the guidance you need.

Get in touch

Common Industry Uses for Blister Packs

Our team has served a wide range of industries over the years, offering custom solutions with the quality and precision that you depend on.

Even within each industry, there are multiple potential uses for blister packs. Below are some of the common uses we design and manufacture blister packs for in-house, but if the item you’re thinking of isn’t on the list, reach out! Our job is to find a solution.

Medical Industry Blister Pack Uses:

• Medical devices
• Medical implants
• Medical and surgical instrumentation

Commercial and Industrial Blister Pack Uses:

• Electronic devices and accessories
• Automotive component packaging
• Oral health products including toothbrushes and dental floss
• Batteries
• Screws, nails, nuts, and bolts
• Protective cases
• Ink cartridges

Blister Pack Benefits

Packaging your product can be as crucial as the manufacturing of your product itself. Packaging can determine a lot of variables, from how attractive your product looks on a store shelf to how protected your product is against wear and tear.

These are some key benefits to choosing a blister pack:

• Protection – Not only do blister packs offer a high degree of protection during both transportation and storage, but you can also increase protection depending on the exact model and design that you choose.
• Lightweight build – The lightweight design is great for handling, and it also means that you’ll benefit from lower transport costs, especially if you’re manufacturing and shipping large quantities of your product.
• Unique design – The unique and wide-ranging design possibilities with blister packs mean that we can adjust the packaging to your exact needs. Our team offers direct consulting to help ensure we’re adding value to your packaging.
• Easily recycled – In addition to so many practical benefits, blister packaging is also easily recyclable, so you can feel good about your packaging choices.

Blister Pack Materials

Our team can help with material selection based on the unique requirements of your packaging needs. In general, blister packaging is comprised of PET, PETG (polyethylene terephthalate), HIP (high impact polystyrene), or PVC (polyvinyl chloride) plastic.

Our engineering team can help you select the best materials for desired properties including:

• Biocompatibility
• Anti-static
• Fire-retardancy
• Impact
• Abrasion resistance

How Blister Packs are Made

Blister packs are manufactured using our custom thermoforming process. Thermoforming involves taking a plain plastic foil (either PET, PETG, HIP, or PVC, as mentioned above) and transforms it into a three-dimensional shape by applying heat and air pressure. The plastic is molded into whatever shape is needed to bring your packaging solution to life.

Valued for being both highly customizable and cost-effective, custom plastic thermoforming at Janco allows us to manufacture single-use plastic parts with a wide range of potential uses. We frequently thermoform plastic in a variety of colors, densities, and thicknesses.

Our team also has trusted industry partners who offer injection molding services, which offer slightly different capabilities. Reach out to us directly to learn more.

Work with Janco for Your Blister Packaging Contract Manufacturing

Our team has been trusted as the go-to for quality contract manufacturing solutions for over six decades.
From the very beginning, it has been our mission to make the manufacturing process easy for you, with a team that has the experience to answer your questions and provide creative solutions for custom packaging needs.

With cutting-edge technology, an expert team of engineers and project managers, and a comprehensive quality assurance process, our team is proud to offer competitive pricing and unbeatable customer service.

Ready to manufacture custom blister packaging aligned with your unique product needs?

Reach out to Janco for the guidance and experience you need to get the job done right.

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In this post, we’ll discuss how to leverage a manufacturer’s expertise and build a better relationship with your vendor.

Benefits of Working With a Thermoforming Contract Manufacturer

Whether you’ve been in business for 50 years or are an emerging start-up, you’ve likely considered using a contract manufacturer to produce or package your products. Here are a few of the benefits of using a contract manufacturer for thermoforming services.

• Fit-for-purpose
• Expertise
• Cost-competitive
• Scalable and flexible
• Fast prototyping and speed-to-market
• Risk mitigation

Thermoforming Fit-for-Purpose

A thermoforming contract manufacturer is dedicated to getting you the product that fits your needs. Instead of buying a stock option, custom thermoforming ensures your component, product or packaging is made right.

By working together with your contract manufacturer’s design, engineering and manufacturing teams, you can get the custom product or packaging you want. At Janco, we have custom thermoforming equipment and in-house designers here to help provide expertise when creating the design for your project.

Contract Manufacturers Have Expertise

Another benefit of having expert in-house teams is that they can help you make key decisions about design and materials. For example, the design and engineering team can help you optimize design, while the manufacturing team can discuss how the production process can be adjusted to produce the best product for your budget.

Some of the complex aspects your contract manufacturer can help you with include:

• Biocompatibility – For medical products and packaging, the materials you use are likely required to be biocompatible.
• Anti-static – Using anti-static materials prevent dust and particles from collecting on and contaminating products produced and packaged in sterile environments.
• Fire-retardancy – A wide range of products must be fire resistant or made with fire retardant materials.
• Impact – Plastics and foams used in the thermoforming process have shock absorbing qualities to protect delicate and sensitive instruments.
• Abrasion resistance – Materials designed to withstand friction, wear, and scratching are often used in products where components are prone to continuous contact or rubbing.

At Janco, our engineering and production teams have over 60 years of experience to help you design the right material and process for creating your component, product or packaging to meet your needs.

Cost-Competitive

As mentioned above, contract manufacturing reduces overhead costs associated with production facilities, equipment, and labor. In addition, thermoforming is an affordable manufacturing process compared to other techniques, giving you high-quality products at a competitive cost.

Taking advantage of the technical expertise of an experienced custom thermoforming contract manufacturer like Janco helps companies reduce costs further. Combined, working with a contract thermoforming manufacturer can be a cost-effective option for producing your product or packaging.

Scalability and Flexibility

When searching for a contract manufacturer, you want to work with a company that has the bandwidth to manage growth or doesn’t lock you into a contract that leaves you with too much product. Look for a contract manufacturer that offers scalability, allowing businesses to easily adjust production volumes based on demand fluctuations.

Whether it’s scaling up during peak seasons or scaling down during slower periods, contract manufacturers can accommodate these changes efficiently.

Fast Prototyping and Speed-to-Market

The nature of the thermoforming process lets companies quickly produce prototypes. Quick turnaround times for prototyping means faster design assessment and speed-to-market.

Working with a contract manufacturer can accelerate the product development and launch process. They have established supply chains, streamlined processes, and efficient production capabilities, enabling businesses to bring products to market faster than if they were producing in-house.

Risk mitigation

Contract manufacturers can help mitigate risks associated with production, such as quality control, regulatory compliance, and supply chain management. Their expertise reduces the likelihood of errors, defects, or delays, ensuring that products meet industry standards and customer expectations.

Focus on core competencies

Outsourcing manufacturing to a contract manufacturer allows businesses to focus on their core competencies, such as research and development, marketing, and sales. By delegating the manufacturing process, companies can redirect their resources and attention to areas that drive growth and competitive advantage.

Extensive Capabilities

Working with Janco, a custom thermoforming manufacturer, gives you access to comprehensive capabilities. This includes equipment like fully-automated inline thermoforming machines, which help ensure accuracy and efficiency. We also have thermoforming cleanrooms certified to ISO 14644-1 Class 8 to meet your medical packaging needs.

The post Benefits of an Expert Custom Thermoforming Contract Manufacturer appeared first on Janco Inc.

For our 60th anniversary, we wanted to highlight a bit about our history and what makes Janco different.

Part of N.H.’s manufacturing history

Janco, Inc. is based in Rollinsford, N.H., located just 90 minutes north of Boston and the major biotech and industrial manufacturing hubs within the surrounding communities. This small town has a long manufacturing tradition, beginning in 1820 with hydro-powered mills built on the Salmon Falls River. These early manufacturing facilities produced wool textiles and later cotton goods.

Manufacturing of textiles in Rollinsford continued into the 20th century and today these brick mill spaces are used by artists and traditional artisans who produce furniture, paintings, and other goods on a small scale.

In addition to the historic mills, Rollinsford also became the home of modern advanced manufacturing facilities in the 20th century, including Janco, which set up shop on its campus on Goodwin Road. It quickly became part of a larger community of advanced manufacturing companies located throughout Southern N.H. and the greater Boston region.

The beginning of Janco, Inc.

Janco was born in George Janetos’ barn in Rollinsford. At the time, George worked at a local contract manufacturer, Spaulding Fiber, which specialized in the use of fiberboard in sporting goods equipment. When George got home, he would head to the barn and experiment with polyethylene plastic resin. He took his experience and the results of those experiments and opened Janco in 1963 with his brothers Paul, Louis and Andrew. The company quickly made its mark with innovations that revolutionized the industry.

Janco was originally focused on industrial applications and developing athletic equipment. Decades later, Andrew saw a market for medical trays, packaging services and medical device assembly in certified cleanrooms. In 1985 Andrew installed the first cleanroom, launching the medical side of the business. It also made Janco the first company to produce thermoformed medical trays inside of a class 8 cleanroom.

Janco, Inc. today

Today, Janco operates a 100,000-square-foot facility that includes seven FDA-registered and ISO-certified clean rooms. The company produces high-quality and cost-effective thermoforming and compression-molded services for both medical and industrial markets, from industry leaders to start ups. All products are made in the U.S., with service available around the globe.

Janco has class 7 and class 8 ISO certified cleanrooms available for use in manufacturing, assembly and packaging services. We also have an extensive range of forming and fabricating capabilities, including laminating and compression molding of plastics and foam for a wide range of applications.

“We owe much of our success to our skilled Janco team,” said President and CEO Mark P. Janetos. “Whatever the project, they go above and beyond to deliver creative, cost-effective solutions. You not only get a skilled vendor, but a partner you can trust every step of the way.”

Want to know more about our capabilities? View our full list of industrial and medical services.

What makes Janco, Inc. different?

Customized service is at the heart of what we do. We base the”Janco Difference” on three C’s:

1. Caring – Every project is different and has specific needs. It’s why we take a customized approach to every project, taking time to answer your questions, offer unique solutions, and ensure you understand every step of the process. We believe long-lasting relationships with our customers take a high level of care.
2. Comprehensive – From design to delivery, we offer expertise and state-of-the-art technology. We’ve designed a thorough quality assurance process that ensures your products are precise, reliable, and completed with comprehensive attention to detail.
3. Competitive – Our customers expect high-quality and cost-effective execution. Our competitive solutions and unbeatable quality are part of what makes us unique

Conclusion

It takes expertise, business insight and dedication to withstand the ups and downs of 60 years in business. Janco, Inc. has earned its longevity, in part, due to its experienced staff, high-quality products and exceptional service. Whether you need a customized product solution or are working with distinct specifications that require precision, Janco’s years of experience will help you get the job done.

Contact us to learn more about our capabilities.

The post Janco Celebrates 60 Years of Thermoforming & Packaging Excellence appeared first on Janco Inc.

Thermoforming is one of the most well-known manufacturing capabilities for a good reason – it’s ideal for a wide range of projects spanning several unique industries and needs.

Our team works with clients from design and material selection through to production and labeling to guarantee your project is cost-effective, precise, and high-quality.

Below, we’re answering the most frequent questions our team gets asked about thermoforming.

What is thermoforming?

Thermoforming is a manufacturing capability used for a wide range of essential projects across several different industries. Our team offers both thin gauge and thick gauge thermoforming, putting our decades of experience to use while bringing your custom products to life.

The process begins by heating a thermoplastic sheet until it is malleable, stretching that sheet into or over a single-sided custom mold, and then holding that position as it cools and solidifies into the desired shape.

Then, the sheet is clamped into a custom holding device and heated by an oven using either convection or radiant heat until softened.

Finally, the sheet is held over a mold and pressed into or stretched over the mold using vacuum pressure, air pressure, or mechanical force. The sheet, once softened, conforms to the shape of the mold and is held in place until it cools, and any excess material is removed.

What industries use thermoforming capabilities?

We provide custom thermoforming for several unique industries, including:

• Medical
• Athletics
• Automotive
• Electronic
• Heavy equipment
• Manufacturing
• And more

What can you make with thermoforming?

Every project we take on is custom, so regardless of your needs, we’ll assess the project and determine how we can help.

Most commonly, our team uses our custom thermoforming capabilities to create:

• Blister packaging
• Covers
• Clamshells
• Automation trays
• Enclosures
• Inserts
• Protective cases
• Industrial process tray
• Automotive component packaging
• Electronics packaging

What are the benefits of thermoforming?

One of the key questions we get asked is why thermoforming is so commonly used across multiple industries. Two of the primary benefits are short lead times (meaning you get your product quicker, without sacrificing quality) and low tooling costs (which means you’ll spend less while still getting a high-quality product).

Quicker production time includes fast prototype development, allowing for any necessary tweaks to be made before your product goes into production.

Other major benefits include:

• The ability for you to provide extensive design input
• A large quantity of colored and paintable plastics to customize your product
• Several unique finish options, including multiple patterns and textures

How do I know what material to use?

Our team of experts is here to assist you with every part of the process, including offering guidance for material selection. Many projects have unique requirements, so we’ll help you understand the best material for desired properties such as:

• Biocompatibility
• Anti-static
• Fire-retardancy
• Impact
• Abrasion resistance
• And more

What materials are used for custom thermoforming?

When you work with Janco, you benefit from our long-standing foam and plastic partnerships that offer a distinct advantage when it comes to sourcing, supplying, and meeting your high-volume, mid-volume, or low-volume needs, with competitive pricing at every level.

We work with a wide range of materials, including:

• PET, PETG, PETE (polyethylene terephthalate)
• HIPS (high impact polystyrene)
• Acrylic
• PVC (polyvinyl chloride)
• Kydex®, a trademarked acrylic/PVC alloy
• ABS (acrylonitrile butadiene styrene)
• PC (polycarbonate)
• PP (polypropylene)
• PS (polystyrene)
• HDPE (high-density polyethylene)
• TPU (thermoplastic polyurethanes)
• TPO Foams (thermoplastic olefins)
• And others, depending on your application

What are your thermoforming capabilities?

Janco’s Core Thermoforming Capabilities

• Bed size: 29″x 32″ gauge range of .007″ to .060″
• Thermoforming and Fabrication Cleanrooms certified to ISO 14644-1 Class 8
• Fully-automated inline thermoforming machines

Heavy Gauge Pressure-Thermoforming

• Bed size 48″ x 72″, Gauge range of .006″ to .500″ with 24″ depth of draw
• In-house design assistance, prototype, REN, and production tooling
• ISO 13485 Certification, FDA Registered
• Thermoforming and Fabrication Cleanrooms certified to ISO 14644-1 Class 8

Custom Thermoforming with Janco

Turn to a team you can trust for the solutions you need.

Our team prides itself on offering value-add services that ensure your products offer the highest return on investment. We work hard to bring your visions to life with custom designs, innovative technology, and high-quality materials – all at an unbeatable cost.

For about six decades, we’ve worked on custom jobs for clients who know that they can trust us for all of their thermoforming needs.

Have a project in mind or want to learn more about our custom thermoforming process? Get in touch with us!

The post Frequently Asked Questions: Custom Thermoforming appeared first on Janco Inc.

From design and tooling through to production, thermoforming is all about choosing the right details to bring your project to the life – the most effective design, the ideal material selection, and a quality cleanroom to conduct the process. At Janco, we work with you to ensure that you’re adding value to your product through every stage of the process.

Below, we’re breaking down the most common questions around thermoforming, from the very basics, to how we operate in our facilities.

What is the thermoforming process?

​​Thermoforming is an essential medical manufacturing capability, used across a range of important projects for several medical sectors. It entails the process of heating a thermoplastic sheet until it is malleable, stretching that sheet either into or over a single-sided mold, and then holding that position as it cools and solidifies into the desired shape.

Once this is done, the sheet is clamped into a custom holding device and heated by an oven using either convection or radiant heat until softened.

Next, the sheet is held over a mold and pressed into or stretched over the mold using vacuum pressure, air pressure, or mechanical force. The sheet, once softened, conforms to the shape of the mold and is held in place until it cools, and any excess material is removed.

What are the benefits of thermoforming?

Several key benefits make thermoforming an ideal means of manufacturing so many products. Two of the primary benefits are the low tooling costs and short lead times, meaning clients can get quality products at an ideal price and with a quick turnaround.

That fast production time includes quick prototype development, allowing for any necessary tweaks to be made quickly before a product goes into production.

Other useful benefits include:

• A large selection of colored plastics
• Extensive finish options, including several patterns and textures
• The ability for clients to have extensive design input

What are the stages of thermoforming?

Our team has a thorough process for every manufacturing capability utilized in our facilities, including thermoforming. Typically, we start by getting a general idea of your needs, including a budget, timeline, materials, and design ideas.

Once a budget and timeline are agreed upon, we begin the design phase. In some cases, clients come to us with specific design needs, whereas others will rely on our team of engineers for help coming up with the right design for their unique needs.

Once the design is settled, we begin prototyping and tooling, building the components and machinery used for production, including custom molds. After prototyping and tooling are complete, your product will go into production. The final step is shipping the product out to you once it’s ready to be used.

Is thermoforming used for medical trays?

Yes, medical trays are one of our most common medical thermoforming projects. In addition, we also commonly manufacture blister packaging, clamshells, protective cases, and more.

Is thermoforming done in a cleanroom?

Our team thermoforms all medical products in our ISO 14644-1 Class 8 certified cleanrooms. To ensure safety and precision on every single job, our medical processes are audited regularly via independent, internal, and FDA inspections. In addition, our cleanrooms are regularly tested to ensure that they are always operating correctly and efficiently.

Our certifications include:

• High Volume Thermoforming ISO 14644-1 Cleanroom Certification-Class 8
• Low Volume Thermoforming ISO 14644-1 Cleanroom Certification-Class 8

What material is used for thermoforming?

• PET, PETG, PETE (polyethylene terephthalate)
• HIPS (high impact polystyrene)
• Acrylic
• PVC (polyvinyl chloride)
• Kydex®, a trademarked acrylic/PVC alloy
• ABS (acrylonitrile butadiene styrene)
• PC (polycarbonate)
• PP (polypropylene)
• PS (polystyrene)
• HDPE (high-density polyethylene)
• TPU (thermoplastic polyurethanes)
• TPO Foams (thermoplastic olefins)
• And others, depending on your application

What are your thermoforming capabilities?

Janco’s Core Thermoforming Capabilities

• Bed size: 29″x 32″ gauge range of .007″ to .060″
• Thermoforming and Fabrication Cleanrooms certified to ISO 14644-1 Class 8
• Fully-automated inline thermoforming machines

Heavy Gauge Pressure-Thermoforming

• Bed size 48″ x 72″, Gauge range of .006″ to .500″ with 24″ depth of draw
• In-house design assistance, prototype, REN, and production tooling
• ISO 13485 Certification, FDA Registered
• Thermoforming and Fabrication Cleanrooms certified to ISO 14644-1 Class 8

Medical Thermoforming with Janco

Thermoforming is an essential component of medical manufacturing, and you need a team you can trust to help you add value to your projects.

For six decades, Janco has been that team. We help bring clients’ visions to life using innovative technology, trusted processes, and high-quality materials at an unbeatable cost.

We work with you through every step of the process, from design through to shipping, guaranteeing that you have a trusted guide to help complete your projects with the care that they deserve. Whether you have a clear vision or need some guidance, we’re here to help.

Have a project in mind or want to learn more about our medical thermoforming process? Our team is happy to talk.

The post Frequently Asked Questions: Medical Thermoforming appeared first on Janco Inc.