Cost guide
How much does custom clamshell packaging cost?
Real factory prices for custom PET clamshells, what tooling costs, and how freight, tariffs and inspection change the landed cost per piece — from actual production orders.
If you are pricing custom clamshell packaging, the number a factory quotes you is only the start. Here is what clamshells actually cost — based on real production orders we have managed — and how to compare quotes on a fair, landed basis.
Factory price: what the plastic costs
These are factory prices from actual orders of custom folding PET clamshells (0.5 mm, mid-size retail product, two sizes sharing one program):
| Order | Quantity | Factory price / piece |
|---|---|---|
| First production run | ~80,000 | $0.070 |
| Smaller follow-up run | ~14,000 | $0.083 |
| Reorder, same mold | ~80,000 | $0.070 |
Notice two things. First, the price barely moved between orders a year apart — once a mold exists, reorders are predictable. Second, the small run cost about 19% more per piece. Volume matters, but not as dramatically as most people expect; freight is where volume really pays off.
What changes the factory price
- Size and depth — more material and slower forming.
- Thickness — 0.4, 0.5 and 0.6 mm are common. Heavier products need thicker walls; we confirm with samples.
- Material — PET/RPET (our default), PVC or PETG.
- Features — hang tabs, embossed logos, locking buttons, insert slots.
One-time costs: molds and samples
A custom clamshell needs a thermoforming mold. Expect anywhere from a few hundred to a couple of thousand dollars depending on size and cavities. Sample rounds (formed samples sent to you by express) typically cost $150–$300 each, and most projects take one to three rounds to get fit and wall strength right.
Tip: embossing your logo into the mold costs nothing per piece afterward — it's a cheap way to look custom without printing.
Freight: the hidden half of the price
Clamshells are light and bulky. A container fills by volume long before it gets heavy, so you are paying to ship space. On one order, the factory price of the clamshells was about $5,650 — and the duties-paid ocean freight for that shipment was $16,500. That is an extreme example (it shipped alone during a period of surging ocean rates), but it shows why you should never compare factory prices alone.
Ways to cut freight per piece:
- Design for nesting so clamshells stack inside each other in the carton.
- Consolidate clamshells with boxes or other goods to fill a container.
- Order fewer, larger runs — a full container is far cheaper per piece than LCL.
Tariffs and duties
Plastic packaging from China carries U.S. duties plus additional tariffs, and the rates have changed several times in recent years. In 2024 our freight partner was quoting an effective tax rate of around 28% on plastic clamshells. Because rates move, we quote DDP (delivered duty paid) so the duty is locked into your price.
Inspection
A third-party pre-shipment inspection runs roughly $330–$750 per visit. On a clamshell run of 80,000 pieces that is under a penny per piece — and it catches cracked hinges, cloudy material and short counts before they reach your warehouse.
Putting it together: landed cost per piece
| Cost line | Typical share |
|---|---|
| Factory price | Largest single line at high volume |
| Ocean freight + U.S. duties/tariffs | Often equal to or more than the factory price for bulky clamshells |
| Inspection, card fees, misc. | A few percent |
| Mold & samples | One-time; spread across the life of the mold |
The right comparison is landed cost per piece at your warehouse versus what your current supplier charges delivered. For many brands buying 20,000+ clamshells a year, factory-direct still lands well below a domestic distributor — but you only know once freight and duty are in the number.
Want your number?
Send us your clamshell spec, annual quantity and current price. We'll return a free landed quote so you can compare it line by line. Prefer to see the options first? Read custom clamshell packaging or clamshell vs. blister packaging.
Frequently asked questions
What is the average price of a custom clamshell?
For a mid-size folding PET clamshell at production volumes, factory prices typically run around $0.07–$0.12 per piece. Landed cost (with freight, duties and inspection) is often two to three times the factory price for this kind of light, bulky item.
How much is a clamshell mold?
A thermoforming mold for a custom clamshell typically costs a few hundred to a couple of thousand dollars depending on size and number of cavities. It's a one-time cost.
Why is freight such a big part of clamshell cost?
Clamshells are mostly air. A container fills up by volume long before it reaches its weight limit, so you pay to ship space, not plastic. Nesting designs and full containers reduce freight per piece.
When is a domestic stock clamshell cheaper?
Under roughly 10,000 pieces, or when a stock size already fits your product, a domestic stock clamshell is often cheaper once mold and freight are counted.