Thermoformed Clamshell Packaging for Health & Beauty

It’s tough work to meet the various packaging requirements for the health and beauty industry, but thermoformed clamshell packaging is almost like a silver bullet. 

Let’s back up a bit. 

Both industries are pretty heavily regulated (yup, make-up packaging is regulated, too…and with good reason). Outside of the product itself, the packaging must meet certain requirements as well. The products cannot be ‘adulterated or misbranded.’ This means that they have to be safe for consumers according to the labeling. Depending on the product, this could vary widely. Depending on the FDA classifications, it might surprise you to learn what’s considered a cosmetic, a drug, a medical device, and more. Each have their own criteria to meet. 

Beyond the regulatory necessities of health and beauty packaging, producers have to be concerned with maintaining the integrity of the product over its shelf life. In this industry, customers love to see the product before they buy it. If it’s expensive, they want to check the quality. If there’s a color, they want to see it. Not to mention that these products are also fairly-high theft items. Package designers need to take all these factors into consideration. 

The Answer: Thermoformed Clamshell Packaging

Why thermoformed clamshells?thermoformed clamshell

This style of packaging is custom formed to every product. It’s fully encased in place, in sturdy plastic. It can withstand the bumps of transportation and delivery. The plastic also ensures freshness of the product. Any factor that extends shelf-life is optimal. Plus, this might be something mandated from the governing regulatory agency.

Clear plastic offers more benefits. It allows customers to see the product prior to purchasing. They don’t have to open it to see the size and shape, the color and any other features.  It reduced the likelihood of damaged or opened product on the floor. Which in turn means less returned product for you. It also deters shoplifting. Thermoformed clamshell packaging isn’t necessarily difficult to open, but it does take a little more effort than cheap cardboard. Well, depending on the strength of the plastic and the determination of the shop lifter. 

And when it comes to labeling, custom printed inserts can meet that need. These inserts, encased within the plastic clamshells, can be personalized in any number of ways to meet the branding and regulatory needs of your product and organization. 

Secure, Durable Presentation

Thermoformed clamshell packaging is a popular option for many industries beyond health and beauty. Contact Sunrise Packaging today to learn more. 

Custom Thermoforming Packaging Options

When it comes to thermoforming packaging, there’s more than meets the eye. 

It’s the ultimate in custom packaging, as the pliable plastic is molded specifically for products. This perfect fit is part of what is driving the market for this specific type of packaging. In fact, PRNewswire estimates that the thermoformed plastics market will hit over $16 billion dollars by 2015. Demand will increase from industries as diverse as healthcare to automotive to construction, driven by this style’s unique properties. So what’s so special about this style of packaging?

Thermoforming Packaging Options

There are a few styles when it comes to thermoformed packaging.  Each one has different applications and advantages, and work differently for different products. Here’s a quick rundown: 

Custom Thermoformed Trays

Highly versatile as well as usable, thermoformed trays are precision-formed to provide the highest level of protection for products. They can even be created with a locking mechanism to ensure that nothing shifts or breaks in transit. These custom trays can be inserted and heat-sealed into boxes or binders to hold not only your products, but companion content as well. USB drives, discs, manuals, you name it. It’s important that your customers experience your products in an ideal setting, right? Custom thermoformed trays create that ideal setting, anywhere and everywhere. 

Thermoformed Blister Packaging

Originally used for packaging aspirin, blister packaging is a lightweight, easy-to-open option for custom thermoformed packaging. Blister packaging is comprised of clear plastic housing your product and adhered to a backing like cardboard or foil. While the idea of easy-to-open packaging might not be at the top of your list of considerations, it’s proving to be a main motivator for some shoppers. Driven by the aging baby boomer market, usability is an increasingly large concern, especially for healthcare and medical devices. 

Custom Thermoformed Clamshells

Clamshells are an increasingly popular option for items that customers want to see before buying. For obvious reasons, it’s not always in the best interests of retailers and producers to have customers opening their products, fidgeting with them, and then walking away. By encasing products in clear plastic, customers can see the exact product they’re looking to purchase. And by making the packaging securely tamper-proof, they know that it’s in perfect condition. We recommend adding a printed insert as well for your branding and more marketing real estate!

Learn More About Thermoformed Packaging Options

Minnesota’s Sunrise Packaging has years of experience in this market. Contact a representative today to find out what style can work for your product!

 

Thermoformed Clamshells Level Up Packaging

Thermoformed clamshells are one of the most versatile styles of packaging. Particularly for retail products because they can be shelved or hung in an area. While blister packs work well for smaller, lighter things, clamshells have more capacity for heavier items. This is because of their construction. 

How Thermoformed Clamshells Are Made & Used

We explained blister packaging as plastic that is heat-sealed onto a separate backing. Think of how eyeshadow is commonly packaged in drugstores: the compact is slightly open, allowing consumers to see the colors. But it’s held securely in place through the thermoformed plastic, and stuck to a piece of cardboard. This allows the customer to open easily from the back after purchase. 

Thermoformed clamshells are similar, but are one single piece connected with a hinge. Just like their namesake. They’re made in a vacuum-forming process, allowing for a tight-fit fastening and total transparency and protection for the products they contain. The main benefits include: thermoformed clamshells

  • Clear evidence of tampering. With the plastic wrap-around feature of clamshells, it’s easy to see when a package has been opened or if a product has been broken. This aids in quality control and also gives the customer a clear idea of what they’re purchasing. 
  • Increased customer satisfaction. We’ve all been in a situation where we purchase something, get it home, and realize that it’s not exactly what we thought. The color might be slightly off, or it’s a different size than expected. With thermoformed clamshells, customers can literally see the product from all angles. It allows them to be completely sure of what they’re buying, without any surprises or compromises on their part. 
  • Enhanced protection for products. The plastic, perfect formed and contoured to the product, acts as a shield during transport and rough handling. It keeps products safe, in place, and perfect for retail presentation.

Marketing Opportunities 

The fun doesn’t have to stop with the thermoformed clamshells. As a full-service facility, Minnesota-based Sunrise Packaging can help you create paperboard inserts (or other materials). These fit inside the clamshell, like the image above. It offers you another platform to enhance the product as well as bring in your branding and carefully-considered copy. 

Whatever your packaging needs are, Sunrise can create the perfect package for you. Contact us today!

Custom Thermoforming for Point of Purchase

Invalid Displayed Gallery

Custom thermoforming is incredibly effective for point of purchase display, beauty, cosmetic, medical, pharmaceutical blister packaging, clamshell, electronic, and other manufacturing industries. Custom thermoforming is very cost effective for high volume orders and repetitive runs. Once your custom tooling is complete for custom plastic packaging, following orders are trouble-free to setup and speedy to turn.

EarSkinz Custom Thermoformed Packaging

Invalid Displayed Gallery

This vibrant custom thermoformed packaging for EarSkinz highlight a wonderful product. The tray assists to tell the story of what the product is, silicone ear bud covers in this case. This design utilizes the smooth and boundless potential of thermoformed plastic trays. An enormous advantage of this custom thermoformed package for EarSkinz is the elimination of extra exterior wraps, boxes or sleeves which diminishes waste, helping the bottom line for EarSkinz. The custom designed tray is covered in front by a clear co-polymer film which is easy to open for the purchaser. Finishing out the packaging is a back label which offers instructions which helps the front to stay clean and stylish.

Custom Designed Clamshells

Invalid Displayed Gallery

I consider custom designed clear plastic clamshells provide an enormous advantage for retail packaging solutions. I think it speaks to people that your package has nothing to hide. Your product is there for the world to see and your customer can see the product and not feel like they have any expectation to be disappointed by misrepresentative contents.

Clamshells provide safety and visibility that are designed specifically to product are frequently custom made with inline thermoforming manufacturing. Plastic material is roll-fed in to the former and takes shape of the Teflon coated aluminum tool that is being applied. Clamshells often are very cost-effective and usually have easy to open functionality that provides a great custom packaging solution.

Advantages of Clamshell Packaging

Invalid Displayed Gallery

Clamshell packaging is distinctive because of its hinged, one-piece design. The hinges allows them to open like a clamshell. Clamshell packaging frequently comes with a single hinge and usually includes a hanger tab so it can be hung on a store hook.

I love the advantages for both the consumer and the manufacturer. Let’s look at a few.

Highly Observable for the Consumer

This type of packaging is usually made using high transparency material. For the consumer, the product inside can be observed from many different angles

Highly Secure for the Manufacturer

Clamshell packaging can be made highly secure, allowing manufacturers to package highly valuable products in them while diminishing the possibility of theft or tampering. This increased security makes it perfect for retail.

Total Enclosure

Clamshell packaging provides total enclosure for the product inside without separate lids or backings. This ensures that the entire package is one piece.

At Sunrise Packaging, we design and manufacture visually interesting and functional plastic thermoformed clamshell packaging. We are a leader in manufacturing thermoformed clamshell packaging solutions to industries such as retail, medical, entertainment, media and cosmetic. We would love to work on your design and concept from start to completion.

 

Blister Packs and Clamshells Everywhere!

 

Start Seeing Blister Packs

When you go into just about any department store or pharmacy, you can often find a wall or two–and an aisle or three–that are covered wall-to-wall in product merchandise. Product, product everywhere, encased in individual blister packs or plastic clamshells. Why? For starters, blister packs are a simple solution to both protecting and displaying retail merchandise. A retail ready solution that has withstood the test of time.


Theft-Deterrent and Marketing Strategy in One

thermoformed plastic blister packs for electronics retailThe most common types of packaging are made of thermoformed thin-gauge plastic. This particular gauge is used for packaging cosmetics, electronics, as well as items vital to the pharmaceutical industry. The main benefits of this packaging category prove the value of blister backs. Thermoformed packaging is tamper-evident–and often tamper proof! This is a great deterrent of theft, and makes for a highly-noticeable attempt. The clear plastic packaging gives the consumer the opportunity to actually see the product in its entirety. A product a consumer can see is a product that they will believe. Finally, high volume markets–such as with electronics–require speedy manufacturing and fulfillment to keep up with consumer demand. Blister Packs and clamshells are a fairly standard design, decreasing the turnaround time on orders


 

A Time-Honored Process

With in-line thermoforming processes, packaging manufacturers are able to produce both blister pack cavities and full two-sided clamshells in an efficient and streamlined way. Roll-fed into the thermoformer, thin gauge plastic travels through an aluminum mold that, when applied with heat and a vacuum, will conform the material to that exact shape and size.

Thermoforming is an old process, only fairly changed since its inception, but it is a proven solution for churning out reliable, protective retail packaging.

Learn More about Blister Packaging

Thermformed Plastic Trays

Invalid Displayed Gallery

Custom thermoforming offers the manufacturer the ability to create a unique packaging solution for anything. That’s right- anything. While thermoformed blister packaging and custom clamshells are generally geared toward the electronic and cosmetic markets, thermoformed plastic trays are applicable to any packaging purpose. The plastic forming process is simple, quick, and economical for production runs large and small, and with custom aluminum tooling, products fit snug into their respective place. Here are some markets that currently use or could greatly benefit from their own custom thermoformed plastic trays:

mechanical/automotive: plastic trays can be formed to hold parts large and small alike. Great for mechanical maintenance or as a presentation for the buyer! Present  a kite with the car manual, title, keys, and throw in a tire gauge for the new car owner!

art/design: perfect tool hold any kind of utensil- keep paintbrushes, pencils, and other tools in a compact and accessible kit. Plastic trays are durable and washable for the messier artist as well…I mean, did Da Vinci worry about paint drips on the ground? I don’t think so.

jewelry/accessories: for an affordable set of jewelry or an organized accessory kit, a plastic tray is perfect for separating by color or style.

wine and spirits: limited edition liquors and wines are a great way to promote high-end alcoholic beverages, new and old. Plastic trays can hold bottles, bottle openers, martini shakers, and more in a comprehensive little kit that true patrons would love to take home!

electronics: in our growing global economy and interweb we’ve got gadgets and gizmos a plenty! Many come with small parts and extra accessories that are valuable to the end use of the product– which is most likely pretty spendy. Keep track of each component with custom plastic trays.

financial/banking: whether it is to hold currency, poker chips, or a banking welcome packet, thermoformed plastic trays can play an integral part in a marketing kit that adds value to the service you provide.

Can you think of any markets that wouldn’t benefit from using plastic trays? Try and stump me by emailing marys@sunpack.com, I’m up for a challenge!

 

 

Sports Electronics Packaging

We found this packaging example on the online gallery, Packaging of the World. Housing sports electronics products, these plastic thermoformed cases offer security and display qualities that are perfect for a retail environment. The challenge that the packaging designer was faced with was the need to refresh the brand to appeal to a younger audience. The designer used accent colors on the packaging in order to categorize products without confusing their targeted consumers. We love this creative use of plastic formed packaging- it does not stay constrained to a classic clamshell or blister pack. These are truly unique packaging solutions that will add value to the product and intrigue more consumers. sportline-potw-01