Thermoformed plastic packaging has many advantages. It’s durable, lightweight, and recyclable. It can be made tamper-proof or leak-resistant, and it’s also cost-effective.
In this article, we’re taking a behind-the-scenes look at our thermoformed plastic packaging process, from initial concept to shipping to you, so you can see, in detail, how food packaging is designed and produced.
Before we dive into the process, let’s define some terms you’ll frequently hear during this process:
What Is Thermoformed Plastic?
Thermoforming is a manufacturing process that uses heat and pressure to form plastic into different shapes. First, the plastic sheet is made by melting plastic resin — which can be virgin plastic or a combination of recycled and virgin plastic material — and extruding it through a die onto chiller rolls, where it is cooled.
To turn the material into food packaging, thermoforming applies vacuum, pressure, and mechanical force to draw the plastic into the shape of the mold. Excess plastic around the edges is trimmed and often reserved for future use. From here, the product may go on for further processing, such as labeling or assembly.
The Thermoformed Packaging Process, Step-by-Step
Our approach to thermoform packaging manufacturing is one we’ve honed for over 30 years — with efficiency, sustainability, and customer satisfaction as our guiding principles. Here’s how we take your custom or stock packaging solutions from initial concept to final inspection.
1. Ideation
Before stepping onto the manufacturing floor, we work closely with our customers to determine the best thermoformed packaging solution.
We begin with assessing needs and identifying problems. Do you need a leak-resistant package for a delivery service? Are you seeking a salad container that extends food shelf life? Are you looking for packaging for a new food product line? Our expert design team have the latest trends and insights you need to create a package that meets your goals.
Next, we dive into how this product compares to similar products on the market. We conduct competitive research on packaging solutions to identify ways to help you stand out on the shelf. From there, we discuss our stock and custom options to determine which is right for you. Working alongside our packaging experts, we brainstorm concepts and create designs backed by extensive research and experience.
By the end of this step, our customers receive concept drawings from our in-house design team for review like the one below.
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Sample concept art for our single-serve cupcake container.
2. Concept Review
In addition to the concept drawings, Lacerta includes realistic renderings to showcase the packaging’s appearance. At this stage, customers also provide feedback and refine their thermoformed packaging options, including color, material, thickness, barrier, and coating.
Before moving forward, we give our clients ample time to review our proposed designs and provide feedback to ensure the end product meets expectations. We use SolidWorks — a 3D CAD design software — to streamline review communications, provide an easy-to-understand visualization of the stock or custom packaging solution, and approve new versions.
3. Prototyping
This is where designs are put to the test.
Our prototyping team provides samples in chosen material options, including recyclable PET, PP, or PCR content. We evaluate features such as snap, lid integrity, film seal, and tamper resistance to ensure they are up to standard. Next, we test the material stressors along with product-package interaction to make necessary changes based on your feedback for production approval.
During this step, we also conduct a life cycle assessment to determine the sustainability attributes of the package. This is especially helpful to our customers who are considering ways to lower their carbon footprint. A life cycle assessment can quantify the impact of the selected packaging, as well as opportunities to further reduce its carbon impact, such as switching to sustainable packaging that uses recycled PET.
4. Tool Design
Next, we move from prototype to production. Each mold is evaluated and measured against the product before its release. If any issues arise, our engineering and manufacturing teams address them before testing and measuring the molds again.
We then meet to collaborate on the optimal run times. Based on the package, our tools can incorporate gun drilling, cooling, robotics, and stacking into the production process.
Once the manufacturing team determines the details of the production runs, we’re ready to start making your packaging!
Our CNC high water pressure aluminum mold cutting machines.
5. Production and Release
We produce thermoformed plastic products at one of three locations nationwide on our fleet of thermoforming machines. Once the molds are inserted into place, the heating process begins.
As we noted above, the plastic is heated until it becomes pliable, and then it’s formed into shape using vacuum, pressure, and mechanical forces. Once the plastic cools and hardens, the excess plastic around the edges is trimmed. The packaging then undergoes rigorous inspection checks during both trial and product runs, which ensures quality and adherence to customer specifications.
From here, your packaging may be labeled or assembled. As an end-to-end manufacturer, our expert design team can create and print custom graphics on lidding solutions — including colors and patterns — that are sure to catch consumers’ eyes.
We Take Thermoformed Food Packaging Seriously
Plastic food packaging isn’t simply a way to package your food products. To us, it’s also the way you keep food safe, prevent it from leaks and spills on the way home, and keep food fresh and delicious longer.
This dedication to packaging is part of why we’ve been Safe Quality Food (SQF 8.1 Level II) certified since 2015. Certification requires Lacerta to demonstrate a rigorous system to manage food safety risks and provide safe products to the food industry. SQF is recognized by the Global Food Safety Initiative (GFSI) as an approved certification body. Many leading food retailers and manufacturers today require GFSI-recognized certification.
We’d love to show you what we do best. For a closer look at our products, request a sample.
