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Clamshell Packaging

One of the most common types of retail packaging on the market is the clear plastic clamshell or box. Referred to as clamshells because they feature two shell-like sides with a middle hinge, these items are typically thermoformed using clear plastic materials. Of course, CD holders are also often referred to as clamshells and these typically consist of 2 to 3 injection molded parts snapped together.

One of the primary benefits of clamshell packaging is that consumers can see the actual product within the package. This can be a very important feature for certain items and it also minimizes the need for product photography. It can be especially helpful for standardizing the packaging for products that come in different colors, styles, or sizes.

Functionality/Styles

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Clamshell packaging is typically chosen when an upscale look is desired. The plastic casing frames and enhances the product while providing a transparent view to the consumer. Clamshells offer excellent protection and can typically be placed on a shell or hung on a peg wall.

While most clamshells utilize 2 sides with a hinged end, some manufacturers make self standing "Tri-Fold" models that contain 3 sides and two hinges. The primary benefit of these packages is that they can be hung on a peg wall, stood on a shelf, or set in a display. They give the retailer a lot of flexibility as to how the product can be displayed. Another newer style is the "mock clamshell" which is a cross between a blister and a clamshell package. These products feature a thermoformed blister with a flange that extends around the exterior of the package to hold a card.

Part Cost

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Clamshell Packaging can be very cost effective depending on the size of the product being packaged. They tend to be quite a bit more expensive than blister packs because they contain more plastic, but for small volume runs, they can be very cost effective.

Part cost is usually a going to be a factor of the type of material you select, the thickness, and the actual size of the clamshell. To some extent, it will also be determined by the size of the machine the product will be run on. Manufacturers using larger machines will have lower labor costs, but typically require longer minimum runs to be cost effective.

Tooling Cost

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One of the primary concerns that many designers have with using a clamshell is the tooling cost. Most thermoformed clamshells will require a set of molds and a corresponding set of cutting dies. Like printing presses, thermoforming machines come in a variety of sizes so the dimensions of the molding area may vary. One can also specify different materials and wall thicknesses to affect the cost. It is important to note that going too thin on the wall can create packages damage easily during shipping and handling.

To overcome the cost obstacle associated with creating a custom clamshell, some thermoforming companies have created standard mold bases or even stock lines of clamshells to handle requests for common sizes and applications. National Plastics, for example, offers its StockClamδline which includes a number of common sizes as well as specific products designed for golf balls and cellular phone accessories. Frank Forst, president of National Plastics adds "by looking at the demand and standardization in a number of industries, we have developed stock product lines and standardized mold bases so that potential customers can minimize the tooling expense typically associated with clamshell packaging.

Assembly

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While clamshells may cost more than blister packs, one area where clamshells have the edge relates to assembly. Simply put, clamshells do not need to be heat sealed to a card the way that blisters do. Rather, most clamshells are designed with friction fit grooves that provide a tight snap together fit. Still, since many retailers have concerns about potential theft from unsealed clamshells and there can also be issues regarding clamshells coming open during the shipping process. Due to this, many packaging engineers will utilize clamshell sealing equipment to ensure a permanent seal.

Shipping

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Costs to ship clamshells are typically minimal as the individual units can be nested together to protect the package and minimize the space needed within the shipping carton.

Outgoing clamshells should be packed tightly enough to restrict movement, but not so tightly as to cause scratching. Some care should be taken not to create shipping cartons that will weight too much. See shipping carton design.

Graphics

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Most clamshells utilize some type of graphical insert similar to a blister card, but others will use a label. While any printer can technically make these products, companies like CardPak specialized in making these cards and offer combination runs that can make them very cost effective.

Beyond the actual card, you'll graphics for your cards that complement the image of your product. More information on packaging graphics.