Its good to see that you're open with your customers. In not going to lie and say i have bought your products. I've always been leary of the price of some points and have been a customer of zwickey ( just got six new heads today in the mail for extras).
I know you must have come up with lots of ideas on how to cut costs, but i will shoot a couple of ideas.
Could you grind an edge onto the heads before you heat treat them and then hone the edge after heat treating? Or do you just use steel that's already hardened to cut blanks from?
Is the finish on the blades that important? What about just parkerizing the steel and soaking it in mineral oil? The blades of old were either blued or painted and they hold up pretty well with years of use. the parkerizing is just an acid bath to pit the surface to absorb oil. What about having them dipped in sodium nitrate? That creates black chroming. That won't wear off anytime soon. They treat tools, bolts, and gun parts with sodium nitrate.
Packaging won't work with shrink wrapped plastic on paper backing? It would hold the blades in place so they can't move to cut their way out easily. They package knives that way.