I don't have to make lunches anymore....yeah..But when I did, sandwiches got old.
I recommend trying Trader Joe's - my husband and kids loved hummus dips & pita or naan breads. TJ's carries so many wonderful single portions of interesting dishes. Try some. My husband really likes the Indian curry rice dishes.
I would cut up fresh veggies on the weekends, celery, carrots, radishes, red bell peppers, snow peas and rotate those through out the week.
Always send a fresh fruit, apples, grapes and oranges travel the best.
Also try the Trader Joe sausages with a side of pesto or garlic buttered pasta. Travels well and is good cold or warm. My son loves the Spinach Chicken sausage. My daughter likes the apple sausages.
And consider using the havla bread for wraps. Lots of recipes on line for wraps, but everything can get wrapped up from leftovers to PB&J. I put turkey breast, arugula, mango salsa and provolone cheese in for the adults. I substitute baby spinach in for the kids because it's softer and way more nutritious than lettuce. The kids prefer simpler food in general.
Hope this helps your hubby's lunches...
Jen