Custom Thermoforming Materials

Custom thermoforming serves a variety of industries. Its versatility is due to the process, which can work with a variety of plastics. Focusing on molding heated plastic, thermoforming is a growing industry serving many other industries, from healthcare to technology. Packaging systems can communicate value to customers. Custom thermoforming is an ideal solution that protects and organizes materials, creating a great experience for users. The aeasthetics don’t stop there, with a variety of plastics used for thermoforming.

These plastic thermoforming materials each have their own qualities and benefits.  Here’s a rundown of some of the materials with which we work at Sunrise Packaging (Blaine, Minnesota). 

Custom Thermoforming Materials & Properties

PET (Polyethylene Terephthalate)Thermoformend trays for the health and beauty products.

PET is a super-clear material, affording customers a great view of a product (we love it for custom vacuum-forming in retail packaging). Another reason why it’s popular? It’s easily recyclable. 

PVC (Polyvinyl Chloride)

PVC is one of the strongest custom thermoforming materials, but just as malleable as any other. PVC is versatile in other ways as well. It can be translucent or colored, opaque or clear. It’s also recyclable, of course. 

 PETG (modified Polythylene Terephthalate)

PETG is a modified version of PET that turns it it into a cross between PET and PVC.  It has a lower melting point than PET, and retains the strength and versatility of PVC. 

RPET (Recycled Polyethylene Terephthalate)

Noticing a trend? PET is a popular base for custom thermoforming. This version–RPET–is made from recycled PET. It’s slightly weaker than standard PET, though. 

PS (Polystyrene)

Polystyrene is among the hardest and stiffest custom thermoforming materials. It’s a popular option for anything that needs to be punched or cut (think CD cases, smoke detectors, etc). 

Custom Thermoforming Applications

These different materials each have slightly different benefits and uses. Depending on what you need from your packaging, Sunrise can recommend the perfect solution.  Contact us today to learn more!

Custom Thermoforming Packaging Options

When it comes to thermoforming packaging, there’s more than meets the eye. 

It’s the ultimate in custom packaging, as the pliable plastic is molded specifically for products. This perfect fit is part of what is driving the market for this specific type of packaging. In fact, PRNewswire estimates that the thermoformed plastics market will hit over $16 billion dollars by 2015. Demand will increase from industries as diverse as healthcare to automotive to construction, driven by this style’s unique properties. So what’s so special about this style of packaging?

Thermoforming Packaging Options

There are a few styles when it comes to thermoformed packaging.  Each one has different applications and advantages, and work differently for different products. Here’s a quick rundown: 

Custom Thermoformed Trays

Highly versatile as well as usable, thermoformed trays are precision-formed to provide the highest level of protection for products. They can even be created with a locking mechanism to ensure that nothing shifts or breaks in transit. These custom trays can be inserted and heat-sealed into boxes or binders to hold not only your products, but companion content as well. USB drives, discs, manuals, you name it. It’s important that your customers experience your products in an ideal setting, right? Custom thermoformed trays create that ideal setting, anywhere and everywhere. 

Thermoformed Blister Packaging

Originally used for packaging aspirin, blister packaging is a lightweight, easy-to-open option for custom thermoformed packaging. Blister packaging is comprised of clear plastic housing your product and adhered to a backing like cardboard or foil. While the idea of easy-to-open packaging might not be at the top of your list of considerations, it’s proving to be a main motivator for some shoppers. Driven by the aging baby boomer market, usability is an increasingly large concern, especially for healthcare and medical devices. 

Custom Thermoformed Clamshells

Clamshells are an increasingly popular option for items that customers want to see before buying. For obvious reasons, it’s not always in the best interests of retailers and producers to have customers opening their products, fidgeting with them, and then walking away. By encasing products in clear plastic, customers can see the exact product they’re looking to purchase. And by making the packaging securely tamper-proof, they know that it’s in perfect condition. We recommend adding a printed insert as well for your branding and more marketing real estate!

Learn More About Thermoformed Packaging Options

Minnesota’s Sunrise Packaging has years of experience in this market. Contact a representative today to find out what style can work for your product!

 

Thermoformed Blister Packaging

The unique needs of different industrial markets can be daunting. If it’s a product shipped overseas, there are international regulatory standards. Some might include considerations of sanitation, creating a completely sterile environment, and more. Luckily, we have something up our sleeve that can usually meet these needs: thermoformed blister packaging fits the bill. 

What is Thermoformed Blister Packaging?

Thermoformed Blister Packaging

The connection between thermoformed blister packaging and use in the medical industry goes back to 1947. Basically, when blister packs were created to house aspirin. While its usage has expanded past storing tablets, it is still a popular option in the healthcare industry. 

To create blister packs, plastic is heated and molded to form cavities and adhered to a stiff backing, like cardboard. The product is then encased and protected in this form-fitting, see-through environment. The surface adds a level of security as well as marketing opportunities. 

Due to its secure nature, thermoformed blister packaging is relatively tamper-proof (at least, it is very easy to tell when a product has been disturbed or ripped open). This takes on especial importance when it comes to healthcare packaging. 

Thermoformed Packaging Uses in Different Industries

While thermoformed blister packaging was originally designed to hold aspirin tablets, it is also used for medical devices themselves. As we mentioned above, housing devices in a sterile environment is of paramount importance in healthcare.  Professionals need to have confidence that their tools are ready for use in any emergency…and if there is any evidence of tampering, they can make a quick decision to use a different one. Blister packaging allows for those evaluations without intense scrutiny. 

Additionally, blister packaging can be extremely lightweight. This means that products can move easily into depressed regions from acts of nature, war, or any other disaster. Moving quickly in an emergency means that any packaging needs to be quickly identifiable and removable as well. The clear product display aids the former; a variety of easy-to-open backings make the latter possible. 

Other Blister Packaging Opportunities

It’s a popular choice for all the above reasons, but we also love that it provides a surface for enhancing the product itself. Customers and users cannot only see the product (and without messing with the packaging), but companies can call attention to certain features or interesting aspects of the product. Like the specific features that set yours apart from the competition. 

Whatever your industry, thermoformed blister packaging provides a great platform to consider for your product. Contact us today to get started!

 

Thermoformed Clamshells Level Up Packaging

Thermoformed clamshells are one of the most versatile styles of packaging. Particularly for retail products because they can be shelved or hung in an area. While blister packs work well for smaller, lighter things, clamshells have more capacity for heavier items. This is because of their construction. 

How Thermoformed Clamshells Are Made & Used

We explained blister packaging as plastic that is heat-sealed onto a separate backing. Think of how eyeshadow is commonly packaged in drugstores: the compact is slightly open, allowing consumers to see the colors. But it’s held securely in place through the thermoformed plastic, and stuck to a piece of cardboard. This allows the customer to open easily from the back after purchase. 

Thermoformed clamshells are similar, but are one single piece connected with a hinge. Just like their namesake. They’re made in a vacuum-forming process, allowing for a tight-fit fastening and total transparency and protection for the products they contain. The main benefits include: thermoformed clamshells

  • Clear evidence of tampering. With the plastic wrap-around feature of clamshells, it’s easy to see when a package has been opened or if a product has been broken. This aids in quality control and also gives the customer a clear idea of what they’re purchasing. 
  • Increased customer satisfaction. We’ve all been in a situation where we purchase something, get it home, and realize that it’s not exactly what we thought. The color might be slightly off, or it’s a different size than expected. With thermoformed clamshells, customers can literally see the product from all angles. It allows them to be completely sure of what they’re buying, without any surprises or compromises on their part. 
  • Enhanced protection for products. The plastic, perfect formed and contoured to the product, acts as a shield during transport and rough handling. It keeps products safe, in place, and perfect for retail presentation.

Marketing Opportunities 

The fun doesn’t have to stop with the thermoformed clamshells. As a full-service facility, Minnesota-based Sunrise Packaging can help you create paperboard inserts (or other materials). These fit inside the clamshell, like the image above. It offers you another platform to enhance the product as well as bring in your branding and carefully-considered copy. 

Whatever your packaging needs are, Sunrise can create the perfect package for you. Contact us today!

Thermoformed Trays Add A Little Something Extra

When it comes to packaging, there’s a lot of emphasis on the outside. Think of a birthday present. If two presents are placed in front of you–one with a sleek, crisp package, the other in a paper bag–which do you want to open first? While the outside of the packaging might be what attracts customers in the first place, it’s what’s inside that retains them. This is where thermoformed trays take center stage…or rather, they provide the center stage. Thermoformed trays for the health and beauty products.

Thermoformed trays are essentially plastic trays, heated and molded into custom shapes and sizes to ensure that your products are held firmly in place. They create a veritable stage for your products. Trays can be placed inside nearly any kind of container, from the popular cigar box to a turned-edge binder.  It’s a versatile solution that many industries include in their packaging designs.  

Here are a few more reasons why this type of custom insert works well for so many different needs: 

Thermoformed Trays Offer Products: 

Protection

To go back to the birthday present example, the only thing more disappointing than a poorly-wrapped present is a broken one. Thermoformed trays are customized to your product, ensuring that it is secure within the larger package. 

Safety

Healthcare packaging and medical device packaging typically utilize thermorformed trays for safety reasons. This industry, focused on life-saving tools and equipment, needs to have their tools safely stored in place where it’s easy to find and use them. 

Organization

Whatever you happen to be packaging with your product, thermoformed trays can keep everything in order. Trays allow you to help customers move through products sequentially.Oor if there are other inserts, to ensure that the most important or relevant ones are easily accessible. 

Ready to Learn More?

Thermoforming is a highly-customizeable process. It starts with designing a layout for your product, selecting materials, and finally moving into the final stages of your custom packaging needs.  Whether you are looking for sustainable, economical, or something else, Sunrise has a solution. Get started today.

Medical Packaging For Boomers

Nearly 27% of the population of the United States was born between 1946 and 1964. Termed the Baby Boomers, this generation has stampeded its way through the decades and are now arriving at retirement age. While aging typically indicates health decline, this generation is bucking that trend (or segments of them are). They're eating better, exercising more, taking preventative measures designed to help them not only live longer, but have a higher quality of life as well. Their expectations are higher than previous generations; baby boomers also tend to have more money and are generally wealthier. They want the best--and they can probably pay for it--in their products, and that includes medical packaging.

Medical packaging presentation packaging for baby boomers

How Baby Boomers Affect Medical Packaging

The enormous influence of the baby boomer generation reflects its size and spending power. Their needs regarding medical packaging are unique to the industry; they love new and innovative styles, but still need to have ease of opening. Think of a bottle of aspirin. It's a common joke, but sometimes the childproof lock defeats adult logic. Add in arthritic hands and possibly declining mental state, and pill-sized pain relief becomes an insurmountable task.  

For the product above, Sunpack created a box with light magnetic closure. This ensures that it won't open accidentally but is easy enough to slip open when needed.

The design of the medical packaging is important as well when it comes to the user's ability to remove it from the package. In the aspirin example from above, it's easy to shake out too many and lose some of the medication. It's not a huge factor with something relatively low-cost, like aspirin, but becomes exponentially more important with the medicine itself. Being able to package an actual device, such as the Axionics device in the picture, securely is step one. Step two is creating a tray which can not only securely hold the device, but allows for semi-easy removal. The thumb holes around each part of the device help ensure a firm grasp prior to lifting.

Vision is another consideration for medical packaging designed for baby boomers. Naturally, as we age, our vision tends to decrease. Medical packaging needs to be clear and concise in design as well as content.  Devices need to be easily identifiable, but that doesn't mean devoid of creativity. For Axionics, you can see the design is deceptively simple, elegant, and with simple fonts to aid comprehension. While white is the dominant color within the design, choosing a bright, single accent color reduces visual clutter.

Karten medical packaging custom tray

Keep It Simple

When it comes to baby boomers and medical packaging, HealthcarePackaging.com said it best:

This consumer segment is looking for brands that will help them take care of themselves and better their lives, without constantly reminding them that they aren’t actually as young as they think they are.

Packaging is great way to connect with an audience. It not only entices people to try it, but if it offers a pleasurable experience, it guarantees referrals and repeat business. Sunpack can help design products that meet this need for your products.

Custom Thermoforming for Point of Purchase

Invalid Displayed Gallery

Custom thermoforming is incredibly effective for point of purchase display, beauty, cosmetic, medical, pharmaceutical blister packaging, clamshell, electronic, and other manufacturing industries. Custom thermoforming is very cost effective for high volume orders and repetitive runs. Once your custom tooling is complete for custom plastic packaging, following orders are trouble-free to setup and speedy to turn.

EarSkinz Custom Thermoformed Packaging

Invalid Displayed Gallery

This vibrant custom thermoformed packaging for EarSkinz highlight a wonderful product. The tray assists to tell the story of what the product is, silicone ear bud covers in this case. This design utilizes the smooth and boundless potential of thermoformed plastic trays. An enormous advantage of this custom thermoformed package for EarSkinz is the elimination of extra exterior wraps, boxes or sleeves which diminishes waste, helping the bottom line for EarSkinz. The custom designed tray is covered in front by a clear co-polymer film which is easy to open for the purchaser. Finishing out the packaging is a back label which offers instructions which helps the front to stay clean and stylish.

Get Your Product to Market Fast

Invalid Displayed Gallery

Thermoforming is far superior to other plastic manufacturing methods when you want to get your product to market in as swift a way as possible. Thermoforming is speedier to implement, more effective in terms of materials and produces a considerably more affordable end-product.

In the final evaluation, thermoforming permits you to make more suitable decisions while still staying within budget. It also lets you have a faster product development cycle that will facilitate you to get your product to the marketplace ahead of your competitors.

 

Victoria Secret’s custom two-piece box

This Victoria Secret’s custom two-piece box illustrates how custom thermoforming so often combines flawlessly with turned edge to create a complete luxury custom packaging solution. I think Victoria’s Secret really triumphs getting their branding message out with this custom designed box!


One of the pieces is a slipcase that covers the main tray. This box is also know as a “drawer” box, and is perfect for kits with important pieces that you need to display. The inside of the box has a plastic thermoformed tray to hold lotions and fragrances securely. Consistent with the fashion trends and color design of the Victoria’s Secret brand, the cover wrap uses  pink and black with a custom pattern. This luxury custom box has two fully telescoped sections and to make it easy to open, a ribbon was included. This box does an incredible job of holding and presenting items in a elegant yet practical manner.