A film with minimal variation in thickness has benefits primarily with regard to the sealing portion of
the process. The film industry refers to a roll with minimal variation in the cross direction of the web as
one with “good profile.” A film with gauge control of less than 5% in the commonly used gauge
ranges of 191-381μm when run with “dedicated” upper and lower thermoforming tools typically
helps preserve the flange of the blister card and can deliver post-forming gauge variation of less than
20μm. Although other factors can influence the result, proper control here helps reduce leaking cavities
and channels during vacuum leak tests made on finished packages. Reduced variation in thickness also
can help minimize gauge bands in rolls that lead to variation in physical appearance and even how
layers may block to one another especially for coated and laminated products that may not have the
slip and release of the base layer. Any alternative film should offer gauge control in the area of
approximately 5% as to not invite problems already solved by the standard choices already available in
the market.