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Extruded Polystyrene for FFS

Polystyrene (PS) has set the standard for thermoformed and form-fill-seal (FFS) rigid food packaging applications — but other polymers are changing that standard. Is PS still the right material for your application?

The Compelling Case for PS Materials

PS has historically been the option for thermoformed and FFS food packaging. It is a durable, versatile material that is easy to thermoform. There are a number of benefits to using polystyrene rollstock for various applications across industries. Explore the advantages below.


PS materials are FDA approved for food contact, making them a suitable option for a range of packaging applications in the food, medical, consumer goods, cosmetics, and even industrial markets.


Polystyrene is an easy material to thermoform and process on FFS equipment. The inherent rigidity of this material offers key functionality such as the snap and score required for certain multipack packaging applications.


Polystyrene materials can be customized to meet both performance and functional requirements with a variety of options including custom blends, enhanced barrier structures, colors, coextruded bi-colors, and high-gloss COEX — and it is compatible with printing processes.

Mechanical Properties

Polystyrene rollstock provides impact resistance and strength, ensuring solid packaging and protection for the product inside.

  • Dairy Packaging Company
  • Dairy Packaging Company

Make It Yours

  • Custom Material Structures

    ● Monolayer
    ● Laminated barrier HIPS
    ● Multi-layer coextruded barrier structures including:
    – PS/EVOH/PE
    ● Symmetrical & asymmetrical configurations

  • Compatible Applications

    ● Thermoforming
    ● Aseptic
    ● Hot-fill (Long dwell, low temp)
    ● Form fill, seal and Deposit fill seal

  • Personalization Options

    ● Custom colors
    ● Custom-designed decorative lamination
    ● Application-based barrier specifications
    ● Specialty topical additive coating
    ● One & two-side corona treatment
    ● Performance additive integration

The Challenges Facing Polystyrene

As a reliable material, PS offers advantages in cost, process compatibility, and mechanical properties. Polystyrene provides significant benefits that make it a suitable material for certain applications.

Recently, health and safety concerns regarding California’s Proposition 65 have brought the use of polystyrene for food applications into question. It is not currently recyclable, making the material unsustainable and unsuitable for high volume consumer applications. This has led many brands to seek a new material: one that is sustainable, food-safe, cost-effective, and able to replicate the functionality of PS material. Industries are seeking a unicorn — and ICPG is ready to deliver.

A New Solution: XPP® Polypropylene

ICPG’S XPP offers a new alternative to PS for FFS applications: this rigid, versatile material serves as a replacement that allows you to upgrade your package without large CAPEX investments or downtime to implement new technology.

XPP Polypropylene Solutions maintain performance, reduce cost, and improve sustainability — all while offering a lower total-cost-of-ownership solution vs PS & PET alternatives. Isn’t it time for an upgrade?

Explore the best replacement for PS: XPP

Talk to a Material Solutions Expert

Looking for the perfect packaging solution for your applications? A material solutions expert at ICPG can help you determine the best fit polymer for your needs.

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