When it comes to packaging food products, selecting the right plastic material is just as important as choosing the right forming technique. Thermoforming offers a fast, cost-effective solution for producing durable, lightweight, and hygienic packaging. But not all plastics are created equal. Understanding the specific characteristics of different materials helps businesses create packaging that meets regulatory requirements, protects product integrity, and enhances shelf appeal.
In food production environments, thermoforming and food packaging go hand in hand. From meat trays to yogurt cups, the demand for precise, safe, and scalable solutions is growing. To help manufacturers make informed decisions, this article explores the most commonly used thermoforming plastics and how each one performs in food-related applications.
Why Material Selection Matters in Food Packaging
Thermoforming plastics used in food packaging must comply with food safety standards, offer resistance to moisture and oxygen, and support efficient forming and sealing. Each packaging format, whether rigid trays, flexible lids, or clamshell containers, requires materials with specific strength, flexibility, and barrier properties.
Choosing the wrong plastic can result in poor sealing, contamination risk, or packaging failures that affect product shelf life and consumer safety. That’s why understanding material behavior during the thermoforming process is essential for any
food packaging operation.
Key Considerations When Choosing Thermoforming Plastics
Before selecting a plastic type for food packaging, manufacturers should evaluate several key factors:
- Food contact safety: Material must be FDA or EU-compliant for direct food contact.
- Barrier performance: Ability to resist moisture, oxygen, and light, depending on the food product.
- Thermal stability: Resistance to heat during forming and sealing.
- Recyclability: Environmental impact and end-of-life disposal.
- Forming properties: How well the material responds to vacuum or pressure forming methods.
Most Common Thermoforming Plastics for Food Products
Several plastic materials have become industry standards in thermoforming and food packaging. Each type offers unique advantages depending on the product being packaged and the packaging design requirements.
Polyethylene Terephthalate (PET and PETG)
Polyethylene Terephthalate or PET
is widely used in food packaging due to its clarity, strength, and excellent barrier properties. PETG, a modified version of PET, provides added flexibility and ease of forming. These materials are commonly found in bakery containers, salad bowls, and clamshells for produce. Their characteristics include:
- High clarity for attractive product presentation
- Good resistance to oils and moisture
- Recyclable and widely accepted in recovery streams
- Excellent forming performance, even with thin walls
Polypropylene (PP)
Polypropylene is a heat-resistant plastic often used for microwaveable containers, yogurt cups, and ready-meal trays. It offers strong sealing capability and can withstand both hot filling and refrigeration. Other characteristics include:
- High heat resistance and chemical stability
- Compatible with heat sealing films
- Good moisture barrier (less effective for oxygen)
- Lightweight and relatively cost-effective
Polystyrene (PS and HIPS)
Polystyrene, including its high-impact variant (HIPS), is often used in dairy packaging, meat trays, and vending machine cups. While not as environmentally friendly as some alternatives, its ease of forming and low cost continue to make it a go-to choice. Characteristics include:
- Good rigidity and form retention
- Affordable and easy to thermoform
- Limited barrier properties (best for short shelf life items)
- Commonly used in disposable packaging
Polyethylene (LDPE and HDPE)
Low-density and high-density polyethylene are known for their moisture resistance and flexibility. LDPE is typically used in lids and flexible packaging, while
High Density Polyethylene (HDPE)
is found in more rigid applications like milk containers and tubs. Shared characteristics include:
- Excellent moisture barrier
- Low cost and wide availability
- Flexible for forming seals and lids
However, HDPE is not as clear as other plastics.
Polyvinyl Chloride (PVC)
Although used less frequently today due to environmental concerns, PVC still finds use in specific thermoforming food applications where high clarity and tight form fitting are needed. It’s often used in
blister packaging
for non-perishable food items. Characteristics include:
- Clear and strong with excellent mold definition
- Good sealing performance
Be aware of concerns about recyclability and plasticizers when using PVC.
Multilayer Coextruded Films
Many food packaging solutions use layered structures combining multiple materials. For example, a PET/PE structure might offer strength and heat sealability. These films are ideal for MAP (modified atmosphere packaging), vacuum sealing, or extended shelf life. Benefits include:
- Customized barrier properties
- Ideal for meat, cheese, and perishables
- Formable and sealable in a single pass
However, they are more difficult to recycle due to multiple resin layers.
How the Right Plastic Supports Efficiency and Compliance
In food production, packaging plays a central role in maintaining safety, freshness, and visual appeal. Selecting the right plastic material affects form cycle time, material waste, and shelf life.
Thermoforming with food-safe plastics offers several advantages:
- Lower per-unit costs for high-volume runs
- Reduced material waste due to efficient forming
- Compliance with FDA and international standards
- Increased flexibility in package design
Matching Plastics with Equipment Capabilities
Thermoforming plastics behave differently depending on heating systems, mold quality, and forming pressure. Some materials like PETG and HIPS are easy to form, while multilayer films or heavy-gauge PP require advanced controls.
Matching plastic material to the right
forming machine
is critical. Machines with zoned heating, dual ovens, and precise vacuum control provide flexibility when running various plastic types or coextruded films.
Industries Relying on Thermoformed Food Packaging
Thermoforming is widely used in food sectors such as:
- Dairy: Yogurt cups, butter tubs, cream containers
- Meat and Poultry: Vacuum trays, MAP packaging
- Bakery: Clamshells for cakes and pastries
- Produce: Clear trays for fruits and vegetables
- Ready-Made Meals: Microwave-safe trays, meal kits
Partner with Belovac for Food-Grade Thermoforming Equipment
Belovac designs and builds
industrial-grade vacuum forming machines
for food packaging operations. With over 30 years of experience, Belovac machines handle food-safe plastics like PET, PP, HIPS, and multilayer films with precision.
- BV C-Class systems for flexible, short-run production
- BV E-Class models with dual heating for challenging materials
- BV A-Class machines for high-output, automated lines
- Customizable sizes for trays, lids, and containers
- Made in the USA with expert support
Whether you’re launching a new product or scaling up, Belovac has the forming technology to meet your needs.
Contact our team or
get a quote
to find the right equipment for your operation.
