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Thermoformed Sheets & Containers

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What is it?

Thermoforming is a process in which a plastic sheet is heated until it becomes flexible and then shaped over or into a mould. After cooling, the formed part is trimmed to create the final product.

Thermoformed sheets are the flat plastic material used at the start of this process. Thermoformed containers are the finished shapes made from the sheet, such as cups, trays, tubs, lids, and food containers.

Plastic sheets and thermoformed containers

Where is it used?

Thermoformed packaging is used across food and selected non-food applications where shape, visibility and practical handling matter.

Fresh produce in a clear thermoformed food tray

Food trays

For snacks, fresh produce, bakery items, ready meals, and other suitable foods.

Cups and tubs for dairy and dessert products

Cups and tubs

For selected dairy, dessert, and beverage applications.

Clear packaging for bakery products

Retail packaging

Display packs, protective inserts, and shaped trays for suitable non-food products.

Clear container with a fitted lid

Protective containers

Packaging where product visibility, a particular shape, or a fitted lid is important.

Key benefits

Design flexibility

Sheets can be shaped to suit the product and packing requirements.

Product visibility

Transparent grades can make the contents easier to see.

Practical handling

A suitable design can help hold and protect products during storage and transport.

Repeatable shapes

Suitable tooling and process control can support consistent dimensions.

Lightweight formats

Some designs may reduce transport weight compared with heavier packaging options.

Materials & technologies

Plastic polymer materials used in packaging

Common material options

  • PET and PET variants: used in some clear, rigid packaging formats.
  • PP (polypropylene): used in selected cups and containers where the grade meets application requirements.
  • HIPS (high-impact polystyrene): used in certain formed packaging products.
  • Other polymers: may be used depending on the supplier, product and required performance.

Typical process stages include sheet preparation, heating, forming, cooling, trimming, and inspection. The exact sequence depends on the machine and product.

Material selection should account for product contact, temperature, stiffness, transparency, sealing, transport conditions, and local recycling options. Confirm the exact grade and suitability with the supplier.

Frequently asked questions

What is the difference between a sheet and a container?

A sheet is the flat starting material. A container is the shaped product made from that sheet.

Can every thermoformed container be used for food?

No. The material and finished packaging must be suitable for the particular food, temperature, filling process, and applicable food-contact requirements.

Are thermoformed containers recyclable?

Some may be recyclable, but this depends on the resin, additives, labels, other components, and local collection and recycling systems.

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