You are looking for packaging that not only protects and presents your product perfectly but also contributes to a better world. That’s a dream that many companies have these days, and we understand that like no other. At the same time, of course, you want the process to run smoothly, the packaging to remain affordable and the functionality to be top notch. The world of packaging materials is changing rapidly with new, more sustainable options entering the market. How do you find your way around them, and which materials best fit your product and goals?
What is thermoformed packaging anyway
Just briefly, thermoforming is a process in which a plastic film is heated until it becomes soft and then formed over a mold into a specific shape. Think trays for cookies, fresh produce or blister packs. It’s an efficient way to create customized packaging. But the success of this process and the end result depends tremendously on the material you choose.
The three pillars of innovative material selection
When choosing the right material for your thermoformed packaging, you’re actually looking at three important things that go hand in hand:
- Sustainability: How environmentally friendly is the material? Does it come from recycled or renewable sources? Is it itself recyclable after use? Does it help reduce waste and carbon emissions? This is the desire of many, but the road to it can seem complex.
- Functionality: Does the packaging adequately protect your product? Consider shelf life through barrier properties, sturdiness during transport, food safety and an attractive presentation on the shelf. Sustainability should never come at the expense of these crucial aspects.
- Cost efficiency: What is the cost of the material itself, as well as the cost of thermoforming, transportation (is it lightweight?) and end-of-life processing? You want a solution that is economically feasible without compromising on the other pillars.
The frustration is often in finding the balance between these three. You want to be sustainable, but you fear it will be more expensive or not work as well. Those fears are not always justified.
a deeper dive into innovative materials
Let’s look at some of the most relevant innovative materials we use for thermoforming:
- Recycled PET (rPET): This is a fantastic development. Instead of using new (virgin) plastic, we make packaging from already used PET, such as from soft drink bottles. This fits perfectly with the circular economy. rPET is clear, strong, has good barrier properties and is very suitable for food packaging. The great thing is that we already have a lot of experience with rPET and the infrastructure for recycling is good. We are strongly committed to this, take a look at our circularsource page to see how we are doing this.
- Bio-based plastics: These are plastics made from renewable resources such as corn, sugarcane or potatoes. PLA (Polyactic Acid) is a well-known example. They offer an alternative to fossil-based plastics. Important to know: bio-based does not automatically mean biodegradable or home compostable. They often require industrial composting facilities, which can be a point of frustration if waste disposal is unclear. They can vary in properties and processability during thermoforming.
- Emerging & specialized materials: Innovation is not standing still. Work is underway on materials such as thermoformed fiber composites, new types of barrier films for extended shelf life (think of our fresh line) and ultra-thin materials that use less raw material. These materials can offer specific functional benefits for certain products, but often require specific knowledge for successful processing.
The complexity of material selection why expertise counts
Okay, so there are several innovative materials. But which one is best for your particular product? That’s where it gets complicated. The “best” choice depends on so many factors:
- What exactly are you packaging (food, non-food, confectionery?)?
- How should it be transported and stored?
- How long should it keep?
- What are the legal requirements?
- What does your consumer or customer’s waste stream look like?
- How do you want your product to present on the shelf?
This is where our expertise comes in. We have years of experience and in-depth knowledge of materials and the thermoforming process. We listen to your wants and needs and help you navigate the options. We look beyond just the material on a roll; we look at the entire chain, from raw material to finished product and recycling.
We are a family business with a no-nonsense mentality. We are hands-on, think inventively and have over 220 molds, as well as specializing in custom solutions. We know what works in practice and how to get the best out of each material during thermoforming to achieve that balance between durability, functionality and cost efficiency. Finding the right partner with this knowledge removes much of that frustration and anxiety. We see it as a challenge to work with you to develop the optimal packaging solution. For example, use our handy new product tool as a first step to structure your ideas.
The future is promising
Developments in innovative packaging materials continue. There is a constant search for even more sustainable options, better functionality and more efficient production methods. Continued innovation is the key and we at MultiTray are fully committed to that.
Conclusion
The dream of sustainable, functional and cost-effective thermoformed packaging is absolutely achievable, especially with today’s innovative materials. The road to it can have challenges, from ambiguities about material properties to concerns about cost and processing. But you don’t have to walk this path alone.
At MultiTray, we combine our material knowledge and thermoforming expertise with a personal, committed approach. We are happy to help you make the right choices for your specific situation. We believe in transparency and making clear agreements. Let’s see together how we can solve your packaging challenges with the latest and most suitable innovative materials.
Ready to explore the possibilities?
Request a free quote or contact us to find out how innovative materials take your thermoformed packaging to the next level. Want to know more about who we are? Then read about us.
Frequently asked questions (faq)
- Are innovative materials always more expensive than traditional plastics?
Not necessarily always. Sometimes the initial material cost is higher, but this can be offset by more efficient thermoforming, lower weight (reduced transportation costs) or savings in waste disposal if the material is easily recyclable. It’s total math.
- Do sustainable materials perform as well as traditional plastics in terms of barrier and strength?
Yes, many innovative materials, such as rPET and certain new multilayer films, offer excellent barrier properties and mechanical strength that are comparable or even better than traditional options. It is crucial to choose the right type of innovative material for the specific application.
- Can I just switch to a bio-based or recycled material with my current thermoforming machines?
While many innovative materials are compatible with existing thermoforming technology, adjustments in temperature, cycle time or tooling may be required depending on the specific material. Our expertise in the thermoforming process helps make this transition smooth.
- How can I be sure that a sustainable material is actually sustainable and not “greenwashing”?
This is a legitimate question and a point of frustration for many companies. Look beyond claims on the packaging. Ask about certifications, the percentage of recycled or renewable material, and the exact waste stream (is it recyclable through existing systems or does it require special handling?). A transparent supplier such as MultiTray can give you full information about this.
