Custom Thermoformed Packaging

AVI Global caters to consumer goods, retail and industrial clients with a full suite of custom thermoformed packaging solutions. Be it blisters, clamshells, trays or tray lids, we leverage our in-house sheet extrusion and plastic thermoforming capabilities to help clients around the world, large or small, meet their packaging and machine specifications with higher precision.

We are ready to be at your service, right from packaging concepts to timely developments of moulds and ancillary thermoforming tools needed to turn your next innovative packaging idea into reality.

Custom Plastic Thermoforming Services

Be it a recycled toothbrush blister, custom medical implant clamshell or protective electrostatic discharge (ESD) tray, together let’s explore new ways to improve your thermoformed packaging costs, sustainability, appearance or functionality.

Custom Clamshell Packaging:

Our custom clamshell offerings ensure the right product protection and presentation depending on the type, size and purpose of your clamshell packaging. We offer a wide choice of materials including PET, PVC, PP, HIPS and laminated structures for an enhanced barrier, locking sealing or performance.

Custom Trays & Lids:

AVI’s range of custom plastic trays and tray lids cater to the product protection, transport and sustainability needs of clients across food, consumer goods, electronics, healthcare and industrial applications.

From bakery or chocolate trays to handling trays for shipping or surgeries, our tailor-made trays designs provide you with the right durability, stackability, denesting properties and hygiene to match your requirements specifically.

Help us understand the purpose of your tray along with the material and thickness desired. 

Custom Trays & Lids:

AVI’s range of custom plastic trays and tray lids cater to the product protection, transport and sustainability needs of clients across food, consumer goods, electronics, healthcare and industrial applications.

From bakery or chocolate trays to handling trays for shipping or surgeries, our tailor-made trays designs provide you with the right durability, stackability, denesting properties and hygiene to match your requirements specifically.

Help us understand the purpose of your tray along with the material and thickness desired. 

Custom Blister Packaging

We manufacture blisters typically for sealing onto backing cards with in-house thermoforming capabilities that offer the flexibility of customized high-precision forming with consistent seal integrity and material thickness. Our custom blister packaging, made with PVC or PET materials, offers superior clarity and an economical way to keep products well protected during transit right until purchase.

Depending on the type of product your blister aims to support, we can offer a range of material thicknesses starting from 150 to 1200 microns.

Why Partner With Us

Design Consultation:

Design Consultation:

Need custom thermoformed packaging but don’t have a drawing? No problem. Our team can help you design packaging that meets your unique needs and goals. We consider factors such as material type and thickness, stackability, machinability and mould layout optimisation during the design process.

Unique Materials:

Unique Materials:

We offer a range of materials, textures and coatings to create custom thermoformed packaging for our partners. Options are PET, RPET, PETG, anti-static PET, GAG PET PVC, PP and HIPS in matt or gloss finishes. Be it a high-barrier or ESD-safe tray or an RPET toothbrush blister, contact us to enhance the functionality of your thermoformed packaging.

In-house Tooling & Mould-making:

In-house Tooling & Mould-making:

We have improved our ability to create custom tools and moulds for thermoforming to reduce development time and cost. Our in-house CNC milling and mould manufacturing capabilities provide control and flexibility in custom thermoforming to benefit our partners.

Quick Turnaround:

Quick Turnaround:

We have complete control over the development process for thermoformed packaging, including in-house rigid PET and PVC sheet extrusion, design thinking, tooling and mould-making. Our team of experienced designers, engineers and sales representatives can quickly address your packaging and machine needs.

Rapid Prototyping:

Rapid Prototyping:

We offer custom plastic thermoforming services that include the timely development of packaging prototypes. We offer two options: 3D printed prototypes or aluminium mould prototypes. 3D printing allows for fast and cost-effective testing of packaging concepts, while aluminium mould prototypes provide a high level of clarity, precision, and quality.

Long-run capabilities:

Long-run capabilities:

We have fully automated thermoforming machines that can produce millions of blisters and clamshells, with minimal human intervention for higher hygiene. Our in-line forming, cutting and stacking processes are ISO-certified and we have experience with many polymeric materials. We can meet high-volume packaging requirements with customisation and quality assurance.

Thin to Thick Gauge Thermoforming:

Thin to Thick Gauge Thermoforming:

We use thermoforming pack materials such as PET, PETG, GAG PET, anti-static PET PVC, PP, and HIPS with thicknesses ranging from 150 to 1200 microns. Our thin gauge thermoforming is popular in the pharma, food and retail industries, and we also specialise in thick gauge thermoformed trays for electronic, medical device and industrial clients.

Low Volume Economies:

Low Volume Economies:

We use a mix of semi and fully automated thermoforming equipment based on your order size. We can efficiently fulfil small-volume orders and are more cost-effective than many traditional in-line thermoformers due to our skilled operators and efficient set-ups which allow us to complete multiple jobs in one shift.

Deep Draw Thermoforming:

Deep Draw Thermoforming:

We manufacture trays and clamshells up to 150 mm deep and larger for specialty applications. Our thermoforming expertise and experience allow us to provide uniform pack thickness and quality for complex shapes and sizes.

Commitment to Excellence:

Commitment to Excellence:

We are willing to take on challenges and can discuss ways to improve your thermoformed packaging. We are a custom thermoforming partner for MNCs, retail businesses, healthcare and industrial clients across six continents. We provide supply-chain comfort and quality assurance for all customers, regardless of their business size or location.

Responsible & Quality-Focused Manufacturing