Thermoformer vs Tray Sealer
Two established food packaging technologies with very different process logic. This guide helps you understand which suits your product, volumes, and budget.
Thermoformer
Forms the tray directly from heated bottom film, inserts the product and seals with top film in a continuous process. The format is fully customisable via mould.
- Continuous roll-to-roll production
- Format defined by mould (maximum flexibility)
- Very low per-pack cost at full capacity
- Ideal for volumes above 3,000–5,000 pcs/day
- Natively integrates vacuum, MAP and skin
Tray Sealer
Seals top film onto pre-formed trays already loaded with product. The tray is purchased externally. The process is simpler to start and manage.
- Fast start-up and immediate format change
- Lower initial investment
- Suitable for multiple SKUs and small batches
- Pre-formed tray cost is higher per pack
- Ideal for 500–3,000 pcs/day
Feature comparison
| Feature | Thermoformer | Tray Sealer |
|---|---|---|
| Thermoformable film from roll | ||
| Pre-formed trays | ||
| Integrated vacuum | ||
| MAP (modified atmosphere) | ||
| Vacuum skin packaging | ||
| Quick format change | ||
| Initial machine cost | ||
| Film cost per pack | ||
| High-speed continuous production | ||
| Suitable for small batches | ||
| Compact footprint | ||
| Custom pack format |
Yes · Partial · No
When to choose each
Choose the thermoformer if…
- You produce more than 2,000–3,000 packs/day continuously
- You want to reduce per-pack cost long-term
- You need a proprietary pack format
- You work with fresh meat, sliced cured meats or fragile products (skin)
- You plan to integrate into an automatic line
Choose the tray sealer if…
- You manage multiple SKUs with different formats
- Volumes are variable or seasonal
- Available floor space is limited
- You want quick start-up with lower investment
- You work with ready meals, deli products or pet food
Indicative investment
Prices vary based on configuration, optional modules (MAP, skin, automation) and integration level. These ranges refer to new machines in standard configuration.
Thermoformer
€ 60.000 – 250.000+
Depending on speed, formats, automation
Tray Sealer
€ 20.000 – 100.000+
Depending on single/double head, MAP, skin
Industry 4.0 / 5.0 incentives and leasing can significantly reduce the effective cost.
Not sure which to choose?
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