Clamshell packaging: protecting and displaying products effectively
Clamshell packaging is a clear plastic form used to protect and display products. It is shaped to fold over an item, allowing full visibility and physical security. Most formats are made from PET or recycled PET (rPET), which are both strong and recyclable. This type of packaging works well for small consumer goods that need to hang in stores or ship safely. Packs can be closed with a snap-fit or sealed edge depending on how the item will be sold or opened. Because they are easy to pack and ship, clamshells help teams launch retail products faster.
• Clamshell packaging is made from two clear plastic sides folded around the product.
• It is often made from PET or rPET for visibility and recyclability.
• Products stay protected with a snap-fit or sealed closure.
• The packaging supports quick assembly and matches common retail formats.
• Inserts and labels carry instructions, warnings, and branding inside the pack.
What is clamshell packaging?
Clamshell packaging is a type of clear plastic pack formed by thermoforming. This process heats a plastic sheet and shapes it onto a mold. The finished pack has two halves joined by a hinge. They fold together to hold the product inside and close either by snapping shut or by heat sealing. The most common materials for this packaging are PET and rPET. These are clear, strong, and easy to recycle. PVC is used less frequently because it is harder to process after use.
Printed inserts slide between the plastic sides to show product details, branding, or barcodes. Labels may also be used on the outside, and in some cases, a folded card wraps around the shell. These features help display key information without covering the view of the product.
Why clamshell packaging works so well for retail
This packaging lets customers see the entire product through its clear outer layer. That helps with decisions in-store because buyers can see the product's color, size, and shape. The closely shaped plastic protects the item inside from scratching or moving during shipping. Its clean finish helps products stand out and look professional on the shelf.
Retailers can easily hang clamshell packs using the euro hole or round punch included in most designs. This helps shelves stay neat and better stocked. Snap-fit closures allow customers to open the pack and use the product again, which is useful for multi-use items. Heat-sealed options offer stronger security by making it harder to open the pack without clear signs. This helps prevent tampering or theft in stores.
Common clamshell packaging uses and formats
Clamshell formats are used across many small consumer products. These include earbuds, chargers, cosmetic tools, batteries, razors, toy parts, and basic medical items like thermometers or braces. Most are packed in PET or rPET of 0.3 to 0.6 mm thickness. This helps protect the product without making the pack too heavy.
There are two main closure styles. Snap-fit clamshells close with pressure and can be reopened. These are good for reusable products or gift packs that need more handling. Sealed clamshells are closed by heat around the edge to make tamper-evident packaging. This style keeps the item secure until purchase. The choice between them depends on how the pack will be handled in store and at home.
Branding usually fits inside as a printed card, placed behind or around the product. This insert can carry your logo, instructions, or barcodes, and stays straight inside the shell. For products that need more printed space or repeated use, some brands use PET boxes instead. These are also transparent, but they are more rigid and shaped like small cases.
Sealing, loading, and quality checks for clamshell packaging
Using clamshell packaging usually starts with hand loading. You place the printed insert, put in the product, and then close the shell. If your product needs a seal, small benchtop machines can apply heat or ultrasonic sealing. This depends on the pack's edge design. To seal correctly, you must control the heat level, pressure, and sealing time. If those are off, the pack might not stay closed or could become damaged.
Before sealing, check these points:
• Cavity size: The product must fit tightly without space to move.
• Insert fit: The branding card should lie flat and remain visible.
• Slot position: Hang holes must align for use on store pegs.
• Closure alignment: Hinges and edges should close straight without gaps.
• Full weight: Check that the filled pack can hang securely without tearing.
You can place extra support like folded card or boxes around the shell for added security during shipping. To simplify setup or test how well your product fits, we offer sealing advice and fit checks.
Sustainability and compliance in clamshell packaging
More companies today seek packaging that is both durable and recyclable. Clamshells made from rPET help meet this goal. rPET keeps its strength and clarity, so it protects and displays well while using recycled plastic. Mono-material designs are also becoming the standard. This means both the shell and insert use the same material, helping with recycling and sorting.
Regulations in Europe are changing to encourage packaging that produces less waste and is easier to recycle. Using PET/rPET clamshells designed for recycling keeps your products compliant with current targets. When we design packs, we reduce thickness where possible and shape inserts to avoid empty packaging space. In this way, each pack uses fewer materials without reducing product protection.
Ready-to-order clamshell packaging with support in every step
We supply ready-to-order clamshell packaging for fast retail launches. These are thermoformed packs made from clear PET, produced in the Netherlands to support reliable supply across Europe. Formats are pre-made to fit many standard product types without the delay of custom development.
Our team helps check insert design, sealing method, and pack strength to guide you toward the best match. This support is useful when you need to find a quick solution or confirm retail fit. Because all formats are in stock, we can help speed up your launch and give you full layout control from the start.
FAQs about clamshell packaging
What products are best suited for clamshell packaging?
Small consumer items like electronics accessories, razors, tools, cosmetics, and light medical supplies often fit well. The clear form shows off the full product and keeps it safe in transit.
How does snap-fit compare to heat-sealed closure?
Snap-fit lets the pack open and close again, useful for reuse or gift sets. Heat-sealed packs stay shut during retail and show if tampered with, which helps with security.
Can clamshell packs be made fully recyclable?
Yes, when using mono-materials like rPET for both shell and insert, the entire pack can go into most PET recycling systems.
What is the typical wall thickness of a clamshell pack?
Most packs range between 0.3 and 0.6 millimeters. This strikes a balance between strength and lightness, keeping the pack firm and clear.
What checks should I do before ordering?
Check if the product fits the cavity, if the insert stays in place, and whether the pack hangs correctly. Also test sealing to avoid weak closures during handling and delivery.
