For high quality custom thermoforming, the process starts with an aluminum tool that plastic is formed by. In order to accurately fit products into a custom clamshell, blister pack, or tray it is important that the tooling match the layout and dimensions of the set.
As a turnkey manufacturer, we offer in-house tooling services to keep production in extremely close proximity to the tooling department to ensure accuracy and close communication. Watch our youtube video below to watch how it’s made. We take all necessary action to make sure that the custom tool works properly in our inline thermoformer, and will produce a mock-up of the product to confirm accuracy and quality. To create an ideal package for retail products, cosmetics, and more, consider custom thin gauge thermoforming to create a tamper evident, eye-catching package that displays your product in a competitive retail environment.
While our turned edge products don’t always make it onto our thermoforming blog, our latest addition to the customizable, cigar-style Netbox™ is a thermoformed window that adds display with rigid protection. Made with a rigid PVC material, unlike other clear windowing that uses flexible PVC, the NetBox™ View from Sunrise Packaging combines turned edge and thermoforming manufacturing processes to offer our clients even more packaging options and custom features to make a completely unique and representative product. The thin gauge PVC material is formed to the desired size and shape of the window in the top of the turned edge box. This way, this “tray” is placed in the die-cut turned edge flat in order to lay flush with the covering surface area. This extra step in planning and production adds accuracy and attention to detail; of which any high-end client would take notice. For more information about the NetBox™ with a View, visit the webpage or contact us directly!
This custom disc album is basic and functional. With chosen materials and custom foil stamp, this black vinyl audio album holds all discs in place in an protective, durable case. Most plastic packaging solutions that you see in retail are transparent in order to display the product and draw in a customer. However, what many purchasers don’t realize is that there are multiple colors, gauges, and properties of plastics that can be thermoformed to create a packaging solution. For example, on our online store we offer thermoformed packaging solutions in black, white, and clear! For custom products, we have the best resources to get the plastic in the color and thickness that is best suited for the project. This black custom audio album is just an example of how a classic vinyl and turned edge album can add value and weight to a disc set.
This thermoformed package was made specifically for a customized webkey. Not to be confused with a flash drive, a webkey is a small device with a standard USB that brings the user to a designated landing page or website. When we provide USBs, flash drives, or webkeys to our customers, they are most often packaged in die-cut foam. This option is quick, economical, and great for large one-time production runs. However, for repeat business, it works out better for our clients to opt for a thermoformed plastic tray. Once tooling charges and production is out of the way, everything else becomes extremely affordable the larger the production runs are. Note how specific the formed plastic is in this photo example- this packaging piece held a metal webkey and enclosed it in a secure closure that is formed into the case.
The visibility offered by clear plastic packaging is extremely useful in retail cosmetics sales. Blister packs are one of the most common solutions used for cosmetic application products because of this factor. Until a shopper has the chance to really examine the colors, application features, and personal benefits of the item, you have not convinced them yet. Blister packaging is easier to open than secure plastic clamshells, which will come into play when the consumer needs to return for more. Branding is easier than ever with blister packaging because you have the opportunity to apply your logo, graphic design, and product information all on the blister card- this serves as the back to the formed plastic cavity. Because many cosmetic products are displayed in-store on racks or pegs, blister packaging offers display features as well as the ability to add tab for hanging. With shelf appeal and tamper-evident security, custom blister packaging is an ideal solution for retail cosmetics.
Probably our most popular stock products are for media packaging; whether that entails USB flash drives, or CD/DVD media, our stock packaging solutions and cases go as far back as VHS and cassette albums. While these forms of media are slowly exiting the market, there are still many customers and companies that rely on disc media; either in libraries, self-help collections, or important computer software. USB and disc media are practically universal, especially as back up storage in case cloud software or wireless internet is temporarily unattainable. Finished with vinyl or turned edge, our multi-disc albums with sealed in pages are extremely economical and easy to customize. Internal components of these albums are thermoformed in our facility, heat sealed to the exterior and ring metals are applied. For multi-disc sets or media applications, consider a semi-customizable solution like thermoformed albums; they save time, money, and serve as a representative package of what the customer has in store.
Customized tooling is a heavy investment, but one with a vast return. While there are many benefits to purchasing standardized clamshells or blister trays, a custom fit will look sharp with your product and protect it accordingly. The video below shows the process we use to form the tooling mold that shapes all of your plastic products. After we are provided with the item being packaged, we take all the necessary steps to provide our clients with a perfect fitting mold. Shown here, the mold being made is designed to hold one of our Flashpads™ for our marketing kit. Depending on size, shape, and quantity, custom tooling services give you complete control of how effective the final mold will be by forming multiple pieces per mold, or safely vacuum and pressure forming a deep cavity. Check out the video to get an idea of how this works!
The cosmetics industry is known for using smart, eye-catching packaging solutions to its advantage. Packaging for cosmetic products can be complicated because it is a selective purchase with lots of competitors, but they also are held to a high standard due to their real life applications. Any cosmetics that are visibly tampered with or poorly packaged will quickly be overlooked by the consumer. There are major health repercussions for using contaminated cosmetic products, and suppliers and retailers alike must be hyper-aware of how they are presenting their product. Thermoformed plastic packaging solutions are ideal for the cosmetic market because they offer the best of both requirements.
Cosmetics are judged and chosen based on their color- that is why clear plastic clamshells and blister packs are ideal for foundations, bronzers, eye-shadows and so on. Thermoformed packaging solutions are also very tamper-evident making it easy for the consumer to choose the item that has been unscathed and ensuring their health and safety. Here are a few examples of plastic clamshells and blister packaging being put to good use for cosmetics and make-up products. Read more about thermoformed packaging at Plastic Ingenuity.
At Sunrise Packaging, we use a combination of vacuum and pressure forming when we manufacture thermoformed plastic packaging products. Thermoforming simply refers to the application of heat to thermoplastic in order for it to take the shape of the mold, however there is much more to it than that. That is where a vacuum forming process comes into play. Mostly used for parts with shallow depth, a vacuum is used to assist the plastic material into the mold so it can be thermoformed evenly. A tool called a plug assist is also used and pressure is applied, which is where the term pressure forming comes from. If only one of these methods are used, the plastic is at risk of bunching up and creating an inferior product.
Material choice is one of the most important decisions you will make when you opt for custom plastic packaging manufacturing. At Sunrise Packaging, we are capable of thermoforming a wide range of thin-gauge thermoplastics into custom blister packaging, protective clamshells, and unique thermoformed trays. However, each thermoplastic material has its pros and cons. If you don’t know where to start, ask your manufacturer what materials they offer and more importantly- what do they have experience with. Some of these plastics can be tricky during the manufacturing process. In the meantime, here is a brief overview of some of our more popular options:
PET Plastics are popular thermoforming materials mostly due to the clarity they offer. PET is best used for retail product packaging because this thermoplastic displays the item while protecting it from external conditions (shipping, shoppers, etc.)
PETG offers transparency just like PET plastics. However, PETG thermoplastic is a bit more durable. Yes, the material can scratch but it will not break so this plastic is best used with valuable items that need extra protection.
HIPS is a clear and impact resistant thermoplastic, but be careful- it is brittle! Possibly prone to cold-cracking, this plastic material is most often seen in CD jewel cases. HIPS can be infused with color if you want to make your packaging solution pop!
ABS combines the best of both worlds in plastics manufacturing materials. ABS thermoplastic is durable enough to make up safety gear and lightweight enough for children’s toys.