What Is Thermoforming in Food Packaging?

What is thermoforming?

Thermoforming packaging is a process where a plastic sheet is heated until flexible and then shaped over a mould using vacuum or pressure. Once cooled, the sheet retains the new form, creating strong and versatile food packaging such as trays, clamshells, and lidded containers.

The thermoforming packaging method is often paired with advanced sealing techniques like vacuum skin packaging where a film shrinks tightly around the food, locking in freshness. It can also be use with modified atmosphere packaging where the air inside is replaced with a protective gas mix to extend shelf life.

This process is widely used in the food sector because it offers a reliable way to protect products, extend shelf life, and enhance presentation. Businesses in central kitchens, butchers, and ready-meal production often rely on thermoforming as a key part of their food packaging strategy - if you’ve ever picked up a premium cut of meat or a microwaveable ready meal, chances are it came in a thermoformed pack.

How does thermoforming work?

So, how does thermoforming work in practice? The process follows a clear order:

1. Heating – the plastic film (bottom web) is heated until flexible.
2. Forming – vacuum or pressure pulls the softened film into a shaped mould, creating a cavity or tray.
3. Filling – the food product is placed inside the cavity.
4. Sealing – a top film (lid web) is heat-sealed over the product, locking it in place.

The result is durable, hygienic packaging that can be tailored to the exact product size. For businesses handling large volumes, thermoforming is highly efficient, with automated machinery designed to produce retail-ready packs at scale.

What’s the difference between thermoforming and vacuum pouches?

Thermoforming packaging creates rigid or semi-rigid trays with strong shelf appeal, ideal for retail-ready products. Vacuum pouches are flexible, cost-effective bags suited for bulk storage and distribution. Both are widely used, but the best option depends on your product and business needs.

Thermoforming advantages and disadvantages

When choosing between thermoforming and vacuum pouches, it’s important to weigh up the thermoforming advantages and disadvantages:

Advantages:

• Extended shelf life with MAP or VSP sealing.
• Retail-ready presentation with shaped trays and printed films.
• Product protection from rigid/semi-rigid packaging.
• Branding opportunities through custom-printed top films.
• Stackable and convenient for retail displays.

Disadvantages:

• Higher initial investment in machinery and film.
• Bulkier storage compared to flat vacuum pouches.
• Less cost-effective for businesses with smaller volumes.

The advantages of thermoforming packaging far outweigh the disadvantages for larger, high volume processors.

Best Uses for Thermoforming

Thermoforming packaging is particularly well-suited to premium food products that benefit from both protection and presentation. Fresh meat and poultry cuts, fish fillets, and seafood portions retain their quality and visual appeal when packed in rigid or semi-rigid trays. Sliced cheese, deli items, and ready meals also perform well in thermoformed packs, especially when a professional, retail-ready appearance is important.

Central kitchens, catering operations, and food processors often choose thermoforming because it allows for efficient stacking, easy handling, and strong product protection throughout transport and storage. For businesses looking to combine durability with excellent shelf appeal, thermoforming is an ideal solution.

Packaging Solutions Tailored to Your Needs

Whether you need thermoforming packaging for premium retail-ready products or flexible vacuum pouches for bulk storage, Weald Packaging can help you find the right solution. Our team is ready to support your business with high-quality, reliable food packaging options, just get in touch today.