Analysis and prevention strategies of the five major causes of blistering on the surface of packaging boxes

Analysis and prevention strategies of the five major causes of blistering on the surface of packaging boxes

Introduction

In today's fierce competition in the high-end consumer goods market, blistering on the surface of packaging boxes has become a fatal defect that affects the value of products. According to data from the International Packaging Association in 2025, the economic losses caused by packaging blistering in the world are as high as 2.7 billion US dollars each year. This article systematically analyzes the five core causes of blistering on packaging boxes from the dimensions of material science, production process, environmental control, etc., combined with Alibaba International Station packaging industry belt data and global laboratory research results, and attaches empirical data and solutions to provide companies with a feasible quality control system.

1. Material moisture imbalance: the invisible battlefield of humidity control

Excessive moisture content of packaging materials is the main culprit of blistering. Experiments by NetEase Design Institute show that when the moisture content of cardboard exceeds 12%, the probability of blistering increases by 58%. If the humidity of the storage environment during the rainy season continues to be higher than 65%, the cardboard fiber can absorb up to 15% of its own weight, forming a steam cavity when bonding with the facial paper (Figure 1).

Solution:

• Use microwave drying technology to pre-treat cardboard and accurately control the moisture content at 8%-10%
• Configure the warehouse with an intelligent constant humidity system (humidity 45%±5%)
• Use aluminized moisture-proof film as an intermediate isolation layer

2. Glue process defects: triple crisis of bonding interface

Glue process problems lead to 35% of blistering cases. When the glue coating amount is less than 40g/m², the coverage is insufficient and gaps are formed; and temperature fluctuations of ±5℃ will reduce the cross-linking degree of polyurethane adhesive by 23%. More seriously, the curing speed of quick-drying glue increases by 3 times in a high temperature environment (＞30℃), resulting in stress accumulation in the film.

Glue type	Ideal coating amount (g/m²)	Temperature sensitivity (℃)	Blistering risk level
Water-based glue	45-50	±3	Medium
Hot melt glue	38-42	±5	High
UV glue	30-35	±1	Low

Data source: Global Packaging Materials Laboratory 2025 Annual Report

3. Out-of-control production environment: destructive effect of microscopic particles

The cleanliness level of the workshop is exponentially related to the blistering rate (Figure 2). When the PM2.5 concentration in the air is greater than 75μg/m³, dust particles form isolation islands in the glue layer, reducing the local bonding force to 32% of the normal value. After a luxury packaging factory introduced an ISO 6 clean workshop, the blistering rate dropped from 8.7% to 0.3%.

Key control points:

• Install an electrostatic dust removal system (dust removal efficiency > 99.97%)
• Maintain a positive pressure environment of 15-25Pa on the operating table
• Employees wear anti-static clothing (surface resistance < 1×10^9Ω)

4. Structural design defects: invisible traps of mechanical conduction

The radius of curvature of special-shaped packaging boxes is directly related to the risk of blistering. When R < 5mm, the flow resistance of the glue increases by 7 times, and bubble nests are easily formed at the corners. What's more serious is that the multi-layer composite structure (paper + PET + hot stamping) produces micron-level peeling stress when the temperature difference is > 10℃ due to the difference in thermal expansion coefficient.

Innovative solution:

• Use topology optimization algorithm to design buffer structure
• Develop nano-composite adhesive with expansion coefficient adaptation
• Introduce laser micropore exhaust technology (aperture 50-80μm)

5. Transport and storage stress: continuous damage of dynamic load

When the vibration frequency is in the range of 8-15Hz, the shear force between the layers of the packaging box reaches its peak, which can completely fail the weak bonding interface. Data from a cross-border e-commerce company shows that the temperature and humidity fluctuations in sea containers cause the blistering rate to be 41% higher than that of land transportation.

Protection strategy:

• Use piezoelectric vibration monitoring tags (accuracy ±0.5G)
• Lay phase change temperature control materials in the container (temperature control range 15-30℃)
• Stacking height is limited to below the critical value of dynamic load

Conclusion

The essence of packaging box blistering is the coordinated failure of the material-process-environment system. By establishing a five-dimensional prevention and control system consisting of a moisture intelligent monitoring network (reference page 1), a glue parameter dynamic compensation system (page 8), a clean production matrix (page 5), a structural simulation platform (page 9), and a logistics stress model (page 4), the foaming rate can be controlled below 0.5%. It is recommended that companies access the Alibaba International Station packaging industry belt data platform to obtain the latest solutions in real time. In an era where packaging is experience, overcoming the foaming problem is the lifeline to protect brand value.