Clamshell Packaging

Visibility. Versatility. Security. All in a Clamshell of a Package

When I say, “clamshell,” what comes to mind? Do you think of an oyster?

That’s exactly what clamshell packaging is – a hinged container that completely surrounds the “pearl” of a product inside.

Why Clamshell Packaging?

Clamshell packaging offers several benefits for your brand:

  • It’s a Branding Boost: A transparent plastic clamshell allows your product to be clearly visible. And a printed insert card provides ample billboard space to tout product features/benefits for consumers.
  • It’s Versatile: With most clamshell packaging, if you can imagine it, Rohrer can create it. It can be just about any size and shape. They can even be designed to meet retailer needs – maybe you need “feet” on the bottom of your clamshell for stability on the shelves or hang holes for j-hook displays. At Rohrer, you can customize without compromise.
  • It’s Secure: Using a clamshell package provides protection for the product, the retailer, and the end user. A custom, thermoformed part holds the product securely in place and reduces the chance of damage during transport. The sealing process used for clamshell packaging also helps to deter theft. Dangerous or sharp items (e.g., knives, tools, saws, etc.) can be viewed and stocked safely in the store via a sealed plastic clamshell.

What are the Components of Clamshell Packaging?

The three components of clamshell packaging include: 1. the plastic cavity or clamshell container; 2. a paperboard insert card; 3. the packaging process to close and seal the clamshell.

Clamshell packaging is typically made into a thermoformed plastic cavity so the product inside is easily visible. Most clamshells also include a paperboard insert card that can be utilized to promote the product’s features and benefits. A variety of heat-sealing options are available for clamshells or they can be sealed using a tab within the package.  

What Types of Clamshells are Available?

The beauty of clamshell packaging is its versatility – this plastic container can be just about any size and shape you can imagine. A well-designed clamshell hugs your product to provide consumers with a full 360-degree view. Clamshells can include feet to stand up on retail shelves and/or hang holes for display flexibility. Rohrer has won awards for some of our unique clamshell packaging designs. We’re happy to help create the perfect clamshell for your product!  

Clamshell Tooling Options: Stock or Custom?

Clamshell packaging is typically made into a thermoformed plastic cavity so the product inside is easily visible.

Once you’ve determined that clamshell packaging is ideal for your product, it’s a matter of deciding on stock TransClam tooling, stock TransClam tooling with custom inserts, or custom tooling. In product packaging, “tooling” refers to the aluminum mold set and cutting dies that are used to form and cut the clamshell during the thermoforming process, so we can bring your clamshell vision to life.

Let’s determine the right type of tooling for your clamshell packaging:  

  • Stock TransClam Tooling: At Rohrer, the Stock TransClam Tooling Program includes a series of pre-made, clamshell tooling in standardized sizes, shapes and styles. Stock TransClam tooling is great if you prefer minimum tooling costs and faster lead times.
  • Stock TransClam Tooling with Custom Inserts: Think of stock TransClam tooling with custom inserts as a combination of Rohrer’s stock and custom tooling programs. A clamshell has two sides. You could utilize one of our standard or stock clamshell forms on one side and a custom insert or cavity on the other side.
  • Custom Tooling: Your brand may prefer custom tooling, so the clamshell package fits your product form “like a glove.” If that is the case, our engineering and design team will work closely with you to develop custom molds and dies specific to your brand and your product line. Custom clamshell tooling is ideal when your brand prefers:
    • Packaging designed specifically for your product

    • Ability to incorporate additional features in packaging

    • Wider selection of materials

    • Higher perceived value over stock parts

    • Larger monetary and time investment

    • Promotes a premium brand look.

Adding a Clamshell Insert Card

Adding a paperboard insert card to your clamshell packaging can help you boost your brand. The billboard space allows you to showcase your product’s features and provide instructions for use.

Rohrer can create the plastic clamshell, the paperboard insert card, and provide the printing and decorating all in one place. Now, we just need to seal the clamshell and get it on the road to retailers!

Sealing the Clamshell

  • Radio Frequency (RF) Sealing: RF sealing uses electromagnetic energy similar to a microwave to heat and bond materials together under pressure. If you have a product that has to be securely sealed, this is the best option; it is the only method to guarantee a hermetic seal. RF sealing works best with PVC or PETG.
  • Hot/Cold Seal: Hot/Cold sealing connects plastic to plastic using thermal energy and pressure to create a bond at the flange of a two-piece package. The bonding process is two stages, starting with a heat and pressure cycle that relaxes the plastic molecules, allowing the bond to be created. Next is a cool-down cycle that allows the seal area to stiffen. A hot/cold seal is typically used in smaller, lightweight packages or for electronics that may be damaged with RF sealing.
  • Ultrasonic: Ultrasonic bonding is created by the mechanical action of a high frequency acoustic vibration of the overlapping plastic surfaces under pressure. A specially designed machine transfers vibratory motion into the plastic via a tool called a “horn”, causing the plastic to rapidly heat and melt. The horn holds the molten plastic pieces together under pressure until cooled. The tooling for this method can be expensive, and the size of the seal area is limited. It may require larger packages to be rotated multiple times to fully seal. However, the quick seal cycle makes ultrasonic sealing an attractive option for large-volume items.
  • Ultraviolet (UV) Sealing: UV sealing involves the use of an adhesive that is activated by exposure to ultraviolet radiation. When exposed to certain levels of UV light, cross-linking of the polymer occurs and it begins to harden and create bonds with the plastic surface. Adhesive cure times range from one to thirty seconds. Tooling costs for UV sealing are minimal, but the seals can be unpredictable.
  • Impulse Sealing: Impulse sealing uses short bursts of energy to heat a sealing bar. The bar is then brought into contact with the mating parts of the package structure. The heat is only applied as long as needed, but the sealing bar remains in contact with the package until the seal is cooled and the bond is created. This process is simple and safe; however, the relatively long seal times make impulse sealing a better option for lower-volume items.
  • Additional Sealing Options: If your product does not require extensive theft/damage resistance, there are other options available. For very small runs, using staples along the flange are a manual but inexpensive method to secure your product in the package. A seal can also be built into the package by designing button snaps to hold the two pieces of plastic together.

Are Clamshells Ideal for My Product and My Market Niche?

Absolutely! Clamshell packaging is a great option for protecting and displaying high-value products. Rohrer has a large, diversified base of consumer product companies across many markets, including, but not limited to:

  • School and Office
  • Health & Beauty
  • Hardware
  • Electronics
  • Sporting Goods
  • Crafts & Hobbies
  • Toys

Let’s add your brand to the list! You’ll be in good company.

How Can I Create the COMPLETE PACKAGE at Rohrer?

Clamshells are another way to STREAMLINE your packaging. Rohrer can create the plastic clamshell, the paperboard insert card, and provide the printing and decorating all in one place. Heat seal and assemble. Ready to hit the road to retailers! Another way to produce the PERFECT PACKAGE at Rohrer.

Contact Us Today

Let us create your clamshell package and print your insert cards at Rohrer. Contact us today

Packaging Solutions

Find the right packaging solution to showcase your product. Click on a packaging style to learn more.