Complete Packaging Solutions custom-makes rigid packaging for your items through our thermoforming process. Thermoforming allows us to take sheets of ordinary plastic, heat them to a specific temperature, and then mold them into custom shapes that fit your items perfectly.
The first part of our thermoforming process includes the design and concept of your exact specifications. Our team will discuss ideas and goals with you and then give you a technical drawing for your review. The overall goal is to blend fit and function to give you a quality product.
Once you approve the design, Complete Packaging Solutions creates a prototype. We pride ourselves on quick turnarounds and handle everything in house to control quality and lead time. You could see your prototype in as little as seven business days after you approve the design. The design-to-prototype process typically takes around 10 days. However, it may take longer because every process we undertake is personalized to your needs. Upon your approval of the prototype sample we will move into production tooling and manufacturing.
Thermoforming represents a process by which a machine heats a thermoplastic sheet to its softening point before stretching it across a mold to manipulate it into the desired shape before it cools and hardens.
If your packaging needs a custom shape to fit snugly against products, thermoforming offers a great choice.
Thermoformed plastic is also sturdy in that it protects products against nicks and dings during transport.
Vacuum forming combines heat and pressure to draw the thermoplastic sheets into the final configuration before it cools. The sheet is placed over a mold, and the vacuumed air moves it into the shape we need.
Pressure forming uses vacuum air along with additional pressure to form more detailed shapes in your packaging.
Conversation is the start of this process. Your chosen packaging solutions company should have detailed conversations with you, including asking questions about your requirements and standards while giving you recommendations on the material and color options and a timeframe for completion.
Design requires input from all sides. Most companies use CAD, or computer-aided design, to create a prototype from precise measurements.
Material selection is an important step. In general, polyethylene terephthalate (PET) is the plastic of choice for thermoforming. This material is rigid and recyclable. PET also comes in many thicknesses and can be colored any way you want, including transparent.
Prototyping creates a physical copy. Before we mass-produce your packaging, we ensure all measurements meet your specifications. This is probably the most important step aside from the CAD process.
Tooling helps your packaging take shape. This part of the process is when your packaging solutions company turns a design into a mold over which the thermoformed packaging will stretch.
Let the thermoforming begin! Once we verify the prototype fits perfectly, we begin mass production of your thermoformed packaging.
Trimming and die-cutting each piece. Remember, your packages start as a sheet of plastic. Once the sheet receives its shape and cools, we trim the sheets so they fit into boxes for shipping.
Shipping to your place. The final step is that we ship the packaging to your place so you can fit them around your products. We can ship items for you as part of our kitting and fulfillment service.
This type of plastic packaging minimizes movement of components. Thermoformed trays come in handy for medical components, kits, gift packs, food, parts that require assembly (like for the automotive industry), and packaging large quantities of individual items in the same box.
Thermoformed trays, when combined with the right sealing technique (like heat sealing and RF sealing), keep items safe and secure during shipping and handling to keep them intact and in place. This is particularly important when you want to showcase some or all of the products in clear packaging so customers can see your products clearly before choosing to purchase them.
For example, you sell a meal-kit that has several different components that people can assemble at home. The meal kit includes several colorful fruits and vegetables to make a salad. It’s important to keep the ingredients separate until assembly to prevent spoilage while giving your products a better chance of staying fresh during refrigeration.
This type of packaging keeps your food fresher by offering sturdiness and sealing your products inside the package. Thermoformed food packaging comes down the line horizontally, then your machines put food inside, and then the seal comes down on top of it to keep foods safe inside.
When you use this type of packaging for foods, you have the potential to reduce damage during shipping while increasing shelf life. This is particularly true for perishable foods that require refrigeration or special handling requirements.
Think clamshells and clear plastic packaging that protects food while maintaining visibility.
When you choose thermoformed packaging for your products, you realize several benefits, including:
Your company has several reasons to invest in this type of packaging.
Complete Packaging Solutions has decades of experience in the packaging industry. We’ve worked with national brands such as L’Oreal, Procter & Gamble, Hasbro, and Hitachi, some of which required thermoformed packaging for their products.
Do you think thermoforming is right for your product line? Contact Complete Packaging Solutions to start the conversation.