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Send to KindleBlister pack is clearly 'key' to adapter visibility
Rapid response quality design
Merrill’s was recommended to Keyspan by the company designing the enclosure (containing the circuitry and wires) of the adapter products themselves. Merrill’s experience in thermoforming as well as rapid response and quality design were key factors in Keyspan’s selection.
“We made the decision to change the packaging fairly late in the process of rolling out the new product. Merrill’s was very responsive coming back to us quickly with samples and a proposal after we gave them some guidance on the general package characteristics we were looking for” Ridenhour explains.
Merrill’s proposed a clear rectangular clamshell formed around the product with a four-color printed glossy coated paper insert for text. The back of the new package has a thermoformed cavity that serves two purposes: it allows the package to stand on the store shelf and for some products it holds the cable part of the adapter. The clamshell also has a hang tab so that it can be displayed on a rack. While different Keyspan products require different shapes to be thermoformed into the sheet all the new packages are the same size: 61/8”x 9½”. This durable package protects the product during shipping and in the retail environment where customers are constantly handling the adapters notes Merrill’s Brian Meltzner. The USB PDA retails for $39.
Keyspan was pleased with the package concept but wanted retailers to see it before finalizing the design. In 1999 it took a sample to Fry’s Electronics a West Coast store chain that provided Keyspan with enough feedback to proceed with the next test of the package.
The next step was to display the pack at RetailVision a show where computer product manufacturers make several 20-minute presentations to a room of potential buyers specializing in their particular type of product. In April 1999 Keyspan focused its three sessions on presenting the change in packaging showing both the older box and the new clamshell. “We got unanimous feedback from buyers that the new clamshell package would be more successful in the stores” notes Ridenhour.
Thermoforming the package
Merrill’s state-of-the-art facility uses microprocessor-controlled thermoformers to make Keyspan’s clamshell package. Temperature settings and other parameters are downloaded into the thermoformer from a “recipe” or program created for the particular package. Klöckner’s vinyl film is pulled by pin chains through the thermoformer where it is heated until it becomes pliable. It then enters a modular aluminum tool that creates the shape of the package. Meltzer notes that “All the tools we use are made of machined aluminum. We built this tool as a modular tool so we’d have the flexibility to remove and add different configurations during the manufacturing process.”
Pressure forming and plug assists are used to make the one-piece hinged blister pack. After each package is inspected it’s nested with other packs inside a corrugated shipping case 20 units/case and shipped to Custom Assembly & Packaging (Richmond VA) for assembly and packing.
Keyspan uses Custom Assembly because it respects and wants to support the contract packer’s mission to provide business and production opportunities for the developmentally disabled in Northern California.
While packing the clamshell is faster and easier than setting up and packing boxes going into the retail store arena with a clamshell required the extra step of radio-frequency welding for tamper-evidence and product security. The products are manually assembled and packed into the clamshells together with a descriptive card and installation CD. Then four sets of three completed packages are put on the turntable of a system from High Frequency Technology (Deer Park NY). An upper die system produces RF seals around the rim of the clamshells.
Notes Ridenhour “We didn’t do this to cut costs but saving money makes it better. We’re very pleased with the new package and have received many favorable comments from retailers since making the change.”
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