#1 - "How are blind packs identified without opening them?"

There are many different methods used to identify the minifigures inside the sealed packs. Figzig usually uses two of the following method to ensure the highest degree of accuracy. Amoung the methods include bar codes, QR codes, bump codes, size, weight, case count, case sequencing, and "feel" method. There are various free downloadable Apps that scan and identify QR codes including Brick Search, Minifig Scan, and omgbricks. Specific methods by set:

Series 1 - 2 : Bar Codes/Feel
Series 3 - 18 : Bump Codes/Feel/Weight
Series 19 - 24 : Weight/Feel/Case Count
Series 25 and newer: QR Codes/Weight
Mario Series 1 - 4 : Case Sequence/Weight/Feel
Mario Series 6/5 and Band Mates : Case Sequence/Weight