Thermoforming is a process of heating thermoplastic sheet and placing it over a mold until cooled. The thickness of the material determines whether the manufacturing process uses rolled sheets (thin gauge) or pre-cut stacked sheets (heavy gauge). Thin gauge material is dominant in the disposable packaging sector, especially in the retail markets. Heavy or thick gauge material is commonly used as permanent components in such things as refrigerators, automobiles and spas to name a few. PVC is the most commonly used material.
Types of Thermoformed Packages
Visipak manufacturers a wide variety of thermoformed packaging solutions that are ideal for nearly any product line. Listed below are several of our more popular options, which include clear plastic clamshells, blister packaging, and thermoformed tray inserts.
Blister Packaging
Ideal for light weight products that will be hung on a wall or display, blister packs are inexpensive, but often require tooling to make and equipment to seal onto cards.
Stock Clamshell Containers
Our line of stock clamshells includes over 200 stock sizes that require no tooling, no special cards and can be assembled without any type of special sealing equipment.
Custom Clamshell Packaging
Our vertically integrated operation allows us to take virtually any product or products and move from design and prototyping to full scale production quickly and cost effectively.
Thermoformed Tray Inserts
We have the design expertise and precision thermoforming equipment to manufacture even the most complicated tray inserts.
Thermoformed Trays with Lids
VisiPak can create all types of containers by combining thermoformed lids that fit over custom-designed trays.
Lidded Film Containers
Our FSSC 22000 Certified operation specializes in producing precision food packaging trays for lidded film container applications.
Thermoformed Tubs
Our unique ability to manufacture deep drawn thermoformed parts has made us the supplier of choice for many plastic packaging tub applications.
Thermoformed Bowls
Our expertise in food packaging and deep drawn, thin gauge products allows us to create innovate products like this collapsible salad container.
Custom Containers
Our design team has developed all types of custom thermoformed containers featuring complex shapes, unique designs and added functionality.
Engineering and Design
VisiPak's full team of skilled and experienced designers utilize advanced technology to measure parts and develop package or tray designs in a quick, accurate and cost effective manner.
Shown here is our 3D scanning technology that allows us to expedite the design process and ensure that our designs are accurate and precise.
Prototyping & Tooling Fabrication
Armed with the information and dimensions from the 3D scanning technology, our team utilizes its over 50 years of design experience and some of the most sophisticated design and manufacturing software to develop the final designs.
These designs are then passed to our in-house machine shop who create prototypes for testing and estimating purposes before moving on to the fabrication of the production tooling.
Manufacturing
Once tooling has been fabricated, it is placed in our precision, thin gauge, in-line thermoforming machines that produce high volume quality parts from a variety of materials. The material moves through the heating section into the forming section where pressure and/or vacuum forces the material onto the mold. The process continues to the next station where the forms are die-cut.
Generally, vacuum forming refers to all sheet forming methods. Pressure aids vacuum forming to push the material into the mold. The added pressure of this process provides greater detail and textured surfaces in the end product. Creating sharp corners is possible with pressure added during the forming process.
Benefits of Thermoforming
Thermoformed plastic packaging has many benefits when compared to optional packaging options such as bags, boxes or other plastic containers.
Cost-effective Customization
Unlike cardboard boxes which printed graphics to be applied to the surface, permanent branding and messaging can be molded into the packages.
Quick Turnaround Time
With in-house design, engineering, prototyping, and tooling fabrication, VisiPak can go from conception to fulfillment in a fraction of the time of others.
Inexpensive Molds
Not only are the molds used in thermoforming significantly less expensive than injection molding, but VisiPak's in house capabilities enhance its affordability.
Our Work
As one of the leading thermoforming companies in the United States, Visipak has supplied thousands of companies with standard, stock and customized packages.
Crunch Pak
Yakima
Clarisonic
Restaurant Chain
Semiconductor Manufacturer
Large Timber Company
Handmoto
Acumed
Global Electronics Company
Thermoforming FAQ
- What is thermoforming?
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Thermoforming is a plastic manufacturing process in which some type of sheet plastic is run through a heating or "thermo" process and then shaped or "formed" into a specific item. Once it is formed, it is typically cooled off to create a finished part or product.
The thermoforming process is mostly used to produce lightweight, durable, and cost-effective packages and components including blisters, clamshells, and trays.
- What are the primary advantages of thermoforming?
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In addition to producing light weight, durable and cost-effective packages, thermoforming is typically used to create clear, plastic packages that allow consumers to see the actual product.
When not permanently sealed, many clamshell packages and clamshell trays can also function as an ongoing container.
- Is thermoforming environmentally friendly?
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While single use plastic packaging is often associated with environmental issues, VisiPak:
Recycles back virtually all of its excess material (scrap) into its production processes - reducing waste and minimizing material usage.
Operates highly-efficient thermoforming machines that generally require less energy than alternatives like injection molding machines.
Utilizes many plastics that are recyclable.
Manufactures mainly lightweight products that reduces transportation costs and associated carbon emissions.
Contact a Team Member for a Free Consultation
Whether you know exactly what you need or want to explore your options, our team is here to help you find a solution for your application, budget and more.
Need to Order a Stock Product?
- Visit our online store for stock products available for immediate shipment.