Choosing a pack
How is a custom thermoformed pack developed?
Short answer
A custom pack goes from brief to production in five steps: you share the product, a sample or drawing, the case count and your packing line; the pack is designed around them (cavity layout, draw depth, material grade); a tool is made; initial samples are checked against the agreed dimensions and tried on your line; then production starts. AVI does design, tooling and forming in-house.
Part of the guide: Pack types explained: punnets, clamshells, trays and more
- StepsBrief, design, tooling, samples, production
- At AVIExtrusion, tool room and forming in-house
Start a custom pack
The five steps
- Brief: product, sample or drawing, fill or count, outer case, packing line, market.
- Design: the cavity layout, draw ratio and material grade are specified for the application and line.
- Tooling: the forming and cutting tool is made around the agreed design.
- Initial samples: checked against the agreed dimensions and layout, then tried with your product and on your line.
- Production: once samples are approved.
Why in-house matters
When one company extrudes the sheet, builds the tool and forms the pack, design changes go straight from the tool room to the forming line, and the sheet grade is matched to the tool from the start.
Related questions
How long does tooling take?
It depends on the cavity count, geometry and design changes. AVI's own tool room avoids waiting for an outside toolmaker; ask for an estimate for your project.
What should I send to start?
The product (or a sample), target fill weight or count, outer case size, packing line details, destination market and any pack you want to match or improve.