Custom Clamshell Cards
A clamshell is a folded plastic shell that closes around a product, and on its own it does nothing for your brand. It is transparent, unbranded and identical to every competitor's. The printed insert is what turns it into a retail product. We produce a lot of clamshell cards at ZEE Packaging and that printed component is where all the brand work happens.
The Shell Sells Nothing
Clamshell cards give a transparent pack an identity.
- A bare clamshell looks generic and unbranded on a peg
- The insert carries your logo, colors and product information
- It gives shoppers something to read while holding the pack
- Barcode and pricing sit on the card rather than a sticker
- Instructions and specifications go where buyers look
- Two printed faces are visible through a clear shell
Most brands ordering clamshell cards do so because a plain shell was costing them shelf presence.
Fit Decides Whether It Works
The insert has to sit correctly inside the shell.
- Too large and it buckles when the shell closes
- Too small and it slides around behind the product
- The hang hole must line up with the shell hole exactly
- Card thickness affects how the shell seals or snaps shut
- Any die cut must clear the shell's internal ribs
- We work from the actual shell rather than a drawing
- Single face insert the simplest of our clamshell cards
- Folded insert printing visible front and back
- Full backing panel filling the whole rear of the shell
- With a die cut cradle holding the product in place
- Two piece front and back separate printed faces
- With a punched hang hole matching the shell
Sizes We Print Regular
Every insert is built to your shell, though these run often:
- 3" x 5" for small tools and accessories
- 4" x 6" for mid size products
- 5" x 8" for larger items
- 2.5" x 4" for compact goods
- 6" x 9" for bulkier products
- Custom sizes matched to your existing tooling
Send us the actual clamshell, since internal dimensions differ from the outer measurement considerably.
Stock And Print
- 14pt to 24pt card stock depending on the shell
- White SBS for vivid color visible through clear plastic
- Kraft board where a natural position suits the brand
- Matte lamination, which resists scuffing inside the shell
- Uncoated stock for a softer artisan look
- One or two color flexo for high volume runs
Color reads slightly differently through plastic. We account for that when proofing, since the shell adds a faint cast over everything printed behind it.
- Paperboard tray as an alternative to a plastic shell entirely
- Recycled card stock across most grades we run
- FSC certified paper, certificate available on request
- Soy based ink through the whole run
- Right sizing so no card is wasted inside the shell
- A backing card and window carton, which uses far less plastic
Where product weight allows, we would honestly suggest looking at a window carton instead. It uses a fraction of the plastic and retailers increasingly prefer it.
How Your Order Progresses
- 100 unit minimum, so a small brand can order properly
- Free proof before anything prints
- Free artwork setup by our own designer
- Physical sample on request to check the fit in your shell
- Urgent turnaround at 5 to 8 business days
- Free shipping worldwide with nothing hidden
Frequently Asked Questions
Do you supply the plastic shell?
We print the card inserts and can arrange shells alongside them, so the whole pack comes from one place.
How do we get the fit right?
Send us the shell itself. Internal dimensions vary from the outer measurement, and a drawing rarely captures the ribs.
Will color look different through plastic?
Slightly, since the shell adds a faint cast. We account for that when proofing rather than matching to a bare sheet.
How much do clamshell cards run?
Rough estimate is $0.05 to $0.16 per unit plain, $0.08 to $0.22 with one color print and $0.14 to $0.35 for full color at moderate quantity. Volume moves it. Shipping is included in our price. This is estimate only, so ask our team for a exact quote.
Can the insert hold the product?
With a die cut cradle, yes. It stops the product shifting behind the card, which looks untidy on a peg.
Should the hole be punched?
It must line up with the shell hole exactly, or the pack hangs crooked. We match it from your actual shell.
Can we go plastic free?
Often, with a window carton or a backing card and board tray. It suits lighter products particularly well.
