Capsule blister cartons are sized in the opposite order to most packaging. You do not start at the capsule and work out. You start at the card, because the card is rigid, it is the thing that jams if the fit is tight, and its size is fixed by the blister tooling long before the carton is drawn.
Published capsule sizes, for reference
Hard capsule shells are made to a standard set of sizes, which is useful when you are planning a pocket grid before samples exist. These are the industry figures, not anything we stock or supply.
| Capsule size | Approximate locked length | Approximate outer diameter |
|---|---|---|
| 000 | About 26.1 mm | About 9.91 mm |
| 00 | About 23.3 mm | About 8.53 mm |
| 0 | About 21.7 mm | About 7.65 mm |
| 1 | About 19.4 mm | About 6.91 mm |
| 2 | About 18.0 mm | About 6.35 mm |
| 3 | About 15.9 mm | About 5.83 mm |
| 4 | About 14.3 mm | About 5.32 mm |
From capsule to card to carton
- Take the capsule size and add the forming allowance. A blister pocket is always larger than the capsule it holds, and the pitch between pocket centres is larger again.
- Multiply by the grid. Pockets across times pitch gives the working width, pockets down times pitch gives the working height.
- Add the sealing margin on all four edges. That margin is where the lidding foil bonds, and it is not optional space.
- Add a tear notch, a perforation line or a suspension hole if the card carries one, since each takes its own margin.
- Measure the finished card and add clearance for the carton, typically a small amount per side so the card slides without being loose.
Depth is the part people underestimate. A blister card is not flat. The formed pockets stand proud of the card face, so internal depth is the card thickness plus the pocket height, multiplied by however many cards stack in the carton. Two cards nested face to face take less depth than two stacked the same way up, and if you plan to nest them, say so, because the insert or the tray has to hold that orientation.
Leaflets, literature and closures
A folded leaflet takes real depth once it is folded down to fit, and it is usually the difference between a carton that closes flat and one that bows. Fold a sample leaflet, measure the folded stack, and add that number rather than assuming paper is thin. If the carton needs to resist casual opening, tuck flaps with a locking slit and a tamper seal are the usual answers, and a straight tuck is easier for a filling line than a reverse tuck.
Child-resistant features are available on request. We do not certify compliance; confirm requirements for your jurisdiction and product.
Ordering, minimum and lead time
The minimum is 100 boxes, priced from about $0.48 per unit at bulk volumes and confirmed on your written quote. The die, the plates, design support, US shipping and a digital proof are included, so a carton drawn to your specific card size does not cost more to tool than a generic one. Production is quoted per product in three lanes, rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days, plus 2 to 5 for delivery, with specialty imported work up to about 12 weeks. Two plants, West Chicago and Guangzhou.
Send the finished card dimensions, the pocket height and how many cards go in each carton with your quote request. If the cards themselves are still being specified, blister cards is the place to start, and custom capsule boxes is where the cartons are ordered.
