When it comes to equipping your business with reliable packaging, it’s never a one-size-fits-all. Many variables need to be considered, including product weights and sizes, automation use, available facility space, industry regulations, and more. Custom thermoformed packaging solutions help meet specific needs because of design flexibility and enhancements, affordable tooling costs, and precise forming dimensions. Utilizing tailored thermoformed plastic packaging provides strategic advantages that are scalable and repeatable across the supply chain.
Learn more about the operational benefits of durable plastic products, including pallets, trays, and containers.
Designs for Intricate Part Dimensions
The versatility of thermoformed plastic packaging provides enhanced product protection and material handling for complex components. Once the part weight, measurements, and desired quantity per pack are determined, a detailed CAD design can be developed. The design is the blueprint to develop the thermoformed tool used to form the custom solution.
Engineering package designs with thermoformed plastic produce solutions with tight tolerances and pinpoint accuracy. This allows a wide range of finished goods to be properly encased as they move through the supply chain. From delicate spools of yarn for the textile industry to heavy compact calipers for automotive manufacturers, a thermoformed solution can help safely transport them.
Tailored Modifications to Amplify Logistics
In addition to customized packaging, tailored add-ons can further increase operational efficiency. Color selection and RFID tags are commonly used to help manage inventory and easily locate goods throughout the supply chain. Molded-in labels and nomenclature are long-term solutions for consistent branding and eliminate secondary labeling efforts. To avoid shifts and falls that can cause injuries and damage, seat belts and buckles are installed to amplify load stability. This also removes the extra step operators need to take to stretch-wrap or band loads.
Additional custom options to increase supply chain efficiency and material handling include:
- Orientation Striping – Custom ID and orientation striping increase supply chain visibility, helping operators quickly identify the correct direction and reduce handling errors.
- Lift Assist Components – Lift plates and hooks can be embedded into heavy-gauge plastic containers that carry substantial weight to help pick up and move seamlessly.
- TPU Inserts – Soft injection-molded inserts can be added to trays for a better part fit and to limit chafing as components are transported in a truck and through a warehouse.
Why Thermoforming Over Injection Molding?
In plastic manufacturing, thermoforming and injection molding are used to produce quality packaging. Thermoforming is the process of heating a rigid sheet until it’s flexible and placing it over a mold to take on that shape. Injection molding melts plastic pellets and uses pressure to push the material into a mold. Although they both create similar items such as reusable pallets, trays, and containers, there are advantages to choosing one over the other.
Tooling Costs
Thermoformed tools are cheaper and allow easier modifications than injection-molded tools because of the material used. Wood and aluminum are softer and cheaper materials than steel that injection molding requires. Also, thermoformed tool designs are less complex and reduce the time needed for engineering and machining. Inexpensive materials and lessened labor requirements make thermoforming a more cost-effective choice for certain projects.
Lead Times
With quick tool development and easier modification, thermoforming can go from concept design to prototyping and then full production within weeks. Injection molding tools are more involved in producing and managing that push production dates with the slightest design change. For projects with low to medium volumes needing a fast turnaround, thermoforming is the ideal option.
Custom Packaging Solutions for Different Industries
Each industry has its own set of rules and regulations, elaborate workflows, and pain points to consider when packaging its products. The flexibility and consistency of thermoformed plastic solutions ensure potential issues are avoided, and goods arrive in perfect condition. Regardless of the application, custom thermoforming is suitable for all industries and their needs.
Automotive
OEMs and tier-one suppliers for the automotive industry manufacture a variety of parts with high densities and intricate shapes. They require durable and returnable dunnage to support their closed-loop supply chains as they ship components throughout plants. Rack base packaging for heavy vehicle doors, caliper trays, and transmission containers is commonly used.
Textile
Textile manufacturers typically deal with delicate materials that require high-performing packaging to maintain their integrity. Peninsula Plastics’ custom yarn packs are engineered to protect raw fibers, spun yarn, and spooled thread while shipping and in storage. Consisting of a pallet as the base, each layer of spools is contained by separators and held together with a lid. This custom thermoformed solution supports automation, is hygienic and easy to clean, and can be stored in wet or dry climates.
Distribution & Warehousing
Fast-paced and demanding distribution environments depend on reusable packaging that can withstand everyday use in warehouses. Constantly handled, ergonomic designs such as strategically placed hand holes and 4-way access pallets keep operations seamless. Custom options, such as ID striping and RFID tags, help track and locate inventory quickly when needed.
Enhance Logistical Performance with Custom Thermoformed Packaging
With companies prioritizing flexible production systems, standard packaging can’t keep up with the challenges of new-age manufacturing. Custom thermoformed solutions deter costly downtimes, easily scale unique supply chains, and support digitized networks for efficient operations.
