How an industrial thermoformer works

Work stations of a thermoformer

A thermoformer works continuously through synchronised sequential stations. The bottom film advances in steps through each station while the top film is applied only in the final sealing phase.

• 1. Bottom film unwinder: continuous feeding of base film
• 2. Heating station: film brought to forming temperature (60–120°C)
• 3. Forming station: compressed air or vacuum stamp trays into the film
• 4. Filling station: manual or automatic with dosers/robots
• 5. Closing station: top film application, vacuum/MAP, heat sealing
• 6. Cutting station: blade or punch separates individual packs

Productivity and formats

Productivity depends on step length (advance per cycle) and cycle speed. Compact thermoformers reach 8-15 cycles/min; industrial modular ones reach 20-25 cycles/min with steps of 400-600 mm.

Compared to tray sealers, thermoformers eliminate the cost of pre-formed trays by producing them directly from film. On large volumes this translates to a 20-35% saving on packaging cost.

• Compact thermoformer: 8-15 cycles/min, step 200-300 mm
• Modular thermoformer: 15-20 cycles/min, step 300-500 mm
• Industrial thermoformer: 20-25 cycles/min, step 400-600 mm

When to choose a thermoformer

A thermoformer is economically justified when volumes exceed 50,000-80,000 packs/day or when producing multiple SKUs with frequent format changes. Below this threshold, a semi-automatic tray sealer offers faster return on investment.

• High volumes (> 50,000 pcs/day): thermoformer required
• Wet products with broth/liquids: in-line forming is more hygienic
• Mixed vacuum + MAP lines: thermoformer handles both
• Multiple SKUs with fast changeovers: interchangeable dies in < 30 min