Custom blister packaging
- Custom secondary packaging designed around your primary blister
- Wallets, titration packs, blister cards, multi-panel and inlay formats
- GMP, FMD serialization, Schedule I/II licenses and Locked4Kids child-resistance in-house
Your primary blister is finished. The packaging around it is where adherence, compliance and brand actually live.
Most pharma buyers arrive with a primary blister that is already validated, or a design locked in with a fill-finish partner. What is missing is the packaging around it: the wallet that walks a patient through a 28-day titration, the child-resistant format that passes F=1 protocols, the multi-panel design that carries leaflet, dosing schedule and artwork on a single piece of board. Off-the-shelf wallets will not deliver that. Every indication, every patient group and every regulatory scope forces a different secondary format.
Ecobliss designs and produces custom secondary packaging around your blister. We do not fill primary blisters ourselves. When the primary pack still needs to be scoped, we think along on material choice and geometry and route the filling through trusted partners. The packaging that reaches your patient, the wallet, the card, the carton, the Locked4Kids format, is engineered, tooled and produced in Echt. Since 1995 we have developed custom secondary formats for Organon, Lundbeck, Sanofi, Merck KGaA, Novartis and Janssen.
Design, components, tooling and machines for the pack around your blister. One partner, one brief, one validated system.
Separate vendors for wallet design, carton printing, child-resistant tooling and contract assembly create hand-offs where adherence features, artwork accuracy and launch dates slip. Ecobliss consolidates the secondary scope. Industrial design and artwork run in-house. Blister cards, wallets and folding cartons are manufactured on our own lines in Echt. Tooling is built per project. The packaging machines are custom-built and customised to run your specific wallet or card format. Paperboard and cold seal substrates are sourced and qualified against your scope; we do not manufacture raw films or foils.
The machine lineup spans manual stations (SB1, EJR) for clinical and niche batches, semi-automatic lines (ERB6, ERB8) for launch volumes and fully automatic platforms (FAB6, FAB8 and CBS30A inline) for commercial supply. GMP, GDP, FMD serialization and Schedule I/II controlled substances run under the same roof. When a primary pack still has to be defined, we think along with you and coordinate with fill-finish partners so the secondary format and the primary are engineered to fit from the start.
Speak with our custom secondary packaging specialistsPatient, indication and regulation define the secondary format. The blister is only the core.
A titration therapy needs a wallet that walks the patient through week-by-week dose escalation and locks the sequence so doses cannot be taken out of order. A pediatric SKU needs a Locked4Kids format certified to ISO 8317 and US 16 CFR 1700.20. An arthritis maintenance therapy needs an opening force low enough for hands with reduced grip strength. A clinical trial kit needs a multi-panel wallet that carries randomisation codes, leaflet and dosing schedule on one piece of board. Each of these is a different secondary format, built around the same kind of primary blister. Ecobliss engineers each from the patient and the regulatory file outward, then tools and runs it on the right machine platform.
A custom wallet or card is a validated system. We keep it running for the life of your product.
Secondary packaging is not a one-off job. It is a validated system that has to hold up across line extensions, market rollouts, artwork updates and regulatory changes. Ecobliss manages the full lifecycle with the same 40-specialist team in Echt, from feasibility through commercial supply. Tooling, validation files and artwork masters stay with us, ready for repeat runs, new SKUs and new geographies. When a new dosage strength, a new market or a reformulation triggers a packaging update, you work with the team that already knows your wallet, your blister and your artwork system. No vendor switch, no re-validation from scratch.
What to expect from your custom secondary packaging project
Product and scope assessment
We review your primary blister (existing or in development), indication, patient group, target markets, regulatory scope and launch window. If the primary pack still needs to be defined, we think along on geometry, material and sealing method and route filling through our partners. Within one week you receive a secondary packaging concept brief covering format options, material recommendations, machine fit and indicative tooling scope.
Unique design and functional prototyping
Our in-house design team develops a unique secondary concept: wallet format, panel layout, opening mechanism, child-resistance, artwork system. You receive physical prototypes in 5 to 10 working days so opening force, readability, dose sequencing and brand feel can be evaluated in the hand, not only on screen.
Tooling, validation and trial production
Custom tooling is built to the approved wallet or card design. Trial batches run under GMP conditions on the machine platform that will supply commercial volume, so the pack you validate is the pack you ship. FMD-compliant serialization is integrated on every line.
Commercial supply and lifecycle management
Full-scale production in our GMP-certified facility in Echt, with GDP-compliant warehousing and call-off scheduling. Tooling, artwork masters and validation files stay in-house for repeat runs, line extensions and new market rollouts.
Send us your primary blister and your brief. We will design, tool and produce the pack around it.
Share your blister specification (or the fact that it still needs scoping), your indication, target markets and launch window. Our team will come back within one week with a custom secondary concept, timeline and budget indication, built around your product, your patients and your regulatory scope.
What packaging engineers ask before choosing a custom secondary partner
What exactly is custom at Ecobliss?
The secondary packaging around your blister: the wallet, the card, the carton, the child-resistant format, the artwork system, the tooling and the machine configuration. We do not manufacture custom blister cavities or fill primary blisters. The primary pack is your responsibility or, when needed, we think along and route filling through our partners.
Do you fill the primary blister with tablets or capsules?
No. Primary filling is not part of our scope. We design and produce the secondary packaging around a primary blister that you supply or that we help you scope with a fill-finish partner. This is the core difference with a fill-finish CMO: we specialise exclusively in the pack around the blister.
What secondary formats can you produce?
Custom wallets (cold seal or heat seal), open wallets, box wallets, multi-panel wallets, dosage schedule and titration wallets, syringe wallets, custom-shaped wallets, blister cards, inlay cards and folding cartons. Each format is designed and tooled per project.
Cold seal or heat seal, how do you decide?
Both are sealing methods for the secondary wallet, not blister structures. Cold seal, which Ecobliss invented in 1995, seals at room temperature and protects heat-sensitive products and artwork quality. Heat seal uses temperature to activate the adhesive and suits specific substrate and barrier combinations. We select based on the product profile, the substrate and the machine platform.
Can you manage serialization, child-resistance and controlled substances?
Yes. FMD-compliant serialization and aggregation are standard on every line. Our patented Locked4Kids platform provides certified child-resistant secondary packaging for EU and US markets and integrates with wallet, card and multi-panel formats. We are authorised to handle Schedule I and Schedule II controlled substances under GMP.
What are typical lead times and minimum volumes?
Indicative concepts and prototypes run in 5 to 10 working days. Tooling and validation timelines depend on format complexity. There is no fixed minimum volume: manual and semi-automatic lines support orphan drugs and niche SKUs alongside high-volume chronic therapies.
Can you help if our primary blister is not yet defined?
Yes. We think along on primary blister geometry, material and sealing approach so the secondary wallet and the primary are engineered to fit from the start. Primary filling itself is handled through our partners, and the secondary packaging is produced by us in Echt.
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