Blister package and method of manufacture

A multi-cavity blister package comprising:

• a thermoformed plastic base substrate formed of a non-PVC polymer material, the base substrate having a plurality of individual thermoformed recessed product cavities wherein each product cavity is configured to retain a product therein and has an associated sealing surface area (SSA) surrounding the product cavity,
• the base substrate having, for each individual product cavity, an associated notched line including alternating severed and unsevered line portions, the severed line portions extending completely through the thickness of the base substrate while the unsevered line portions maintain at least some uncut (integral) thickness of the base substrate intact;
• an integral peelable cover layer removably attached to the upper surface of the base substrate for sealing the plurality of individual product cavities, wherein each SSA is disposed and configured to be removably attached to a lower surface of the peelable cover layer so as to enclose the product in each sealed individual product cavity in a sealed environment,
• the attached cover layer and base substrate forming the multi-cavity blister package having a plurality of separable sections defined by section lines cut through a thickness direction of the cover layer and base substrate, each section including at least one individual product cavity and associated notched line wherein the associated notched line extends across a portion of the SSA of the individual product cavity, is spaced apart from the individual product cavity, and extends between two points on a perimeter of the section, the perimeter of the section being defined by one or more outer edges of the base substrate and the section lines, or by the surrounding section lines if the section does not border an outer edge of the base substrate, such that the associated notched line separates a corner or other edge portion of the section from a remaining portion of the section, and
• wherein the corner or other edge portion of each section, after separation of the section from the base substrate, is configured to be bent and broken off by a user at the at least one associated notched line to form a pull tab that includes the broken off portion of the base substrate and the integral cover layer sealed thereto, enabling a user grasping the pull tab to peel back and separate the integral cover layer from the SSA surrounding the individual product cavity of the section to open the sealed environment and enable release of the product from the individual product cavity.