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Custom Thermoformed Packaging

ICPG helps manufacturers develop custom food containers for their unique needs.

Thermoforming: How it Works

Thermoforming is a process used to create custom molded plastic packaging for various applications, such as disposable single serve and shelf stable food containers. This process includes heating rigid extruded rollstock to soften it in preparation to mold the container. When the plastic cools, it retains the shape of the mold. At this point, the material can then be trimmed out of the rollstock for use in its target package application.

Thermoformed Packaging Applications

Thermoforming is a complex process that enables the converter to create packaging at scale for a diverse range of rigid food packaging applications. It is particularly well suited for disposable food containers, trays, clamshells and platters, which can be sealed with a film or fitted with a lid. Example applications include fresh food and foodservice items including coffee cup lids, takeout containers, yogurt cups, pre-packaged bakery and dessert items, berry baskets, ready-to-eat and freezer-to-microwave meals, as well as barrier and shelf-stable items including coffee pods, applesauce cups, pet food containers, guacamole, salsa, and hummus dips.

Make It Yours

  • Thermoformed Packaging Structure Configurations

    ● Monolayer
    ● Barrier & non-barrier laminations
    ● Multi-layer barrier & non-barrier coextrusion
    ● Symmetrical & asymmetrical structures

  • Material Solutions

    ● High Density Polyethylene (HDPE)
    ● Polypropylene (PP)
    ● Polystyrene (PS & HIPS)
    ● PET & RPET
    ● XPP Solutions
    ● Barrier materials:
    – EVOH
    – RE-BA – Re-imagined Barrier Technology

  • Personalization Options for Thermoformed Packaging

    ● Custom colors
    ● Clear & clear-tinted PP & PS
    ● Custom decorative lamination
    ● Performance additives
    ● Topical additive anti-fog and silicone coating
    ● Mineral filler blending
    ● Corona treatment
    ● Custom barrier specifications

  • Support Services

    ● Custom development process
    ● Design consultation
    ● On-site technical support

Material Solutions for Thermoformed Packaging

As the packaging industry continues to evolve, you have a choice between many polymers that are well-suited for thermoforming. These may include high density polyethylene (HDPE), polypropylene (PP), polystyrene (PS), PET/RPET, and EVOH materials. As you determine the best material for your application, there are certain considerations to take into account. You want a material that fits your process and meets the needs of your application while remaining sustainable and cost-effective. If you’re looking for the ideal solution, ICPG can help. We offer a range of high-quality materials for thermoformed packaging — and we have the expertise to help you determine the best fit.

Explore ICPG’s Materials & Applications

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 polymer for your needs.

Let’s Talk

  • Superior Support

    Trying something brand new? Tap into our on-site technical support services to help you through the development process— one material at a time.

  • Reliable Resources

    Uncover an expertly crafted collection of food packaging know-how in our Industry Insights blog.

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  • Sustainably Focused

    Discover how our methods and materials reduce, reuse, recycle and reinforce our everyday dedication to sustainability.

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  • Custom Design Process

    Let’s collaborate to advance innovation. Explore exactly what your customized packaging is capable of.