Thermoforming

In conversations with our clients, especially in automotive, electronics and intralogistics, our experts often hear a similar story, a constant struggle to find a solution that is:  

• durable enough to withstand tough conditions,  
• light enough to reduce transportation costs, and  
• customizable to fit seamlessly into their automated processes.  

The challenge is finding a balance between protection, efficiency, and sustainability — all while managing tight budgets and stringent environmental regulations.  

At Utz Group, we understand these pain points, and that’s why we offer a solution that checks all the boxes: thermoforming. This versatile technology allows us to create custom packaging that solves these issues, providing the perfect balance of strength, precision, and sustainability. 

Thermoforming is a manufacturing process where heated plastic sheets are molded using a vacuum to create custom shapes and designs. This technology is especially useful in creating durable, reusable trays, containers, and other packaging products that need to meet the exact specifications of various industries.

Thermoforming offers several key benefits that make it an ideal choice for companies looking to optimize their packaging operations. 

1. Resource efficiency

One of the greatest strengths of thermoforming is its ability to optimize the use of raw and auxiliary materials. The process minimizes waste by using only the amount of plastic necessary to form each product. Thermoforming can reduce material usage by up to 30% compared to injection molding. This also translates into significant cost savings during transportation. For instance, a 20% decrease in packaging weight can lead to approximately 10-15% savings in fuel costs for large-scale shipping operations.

2. Cost efficiency 

Thermoforming requires significantly lower tooling costs compared to injection molding. For large parts, such as transport packaging solutions, thermoforming can result in savings of up to 50% in tooling expenses. The overall production cost is also reduced since thermoforming requires less raw material and energy consumption, making it an affordable option for creating durable, large-scale packaging solutions.

3. Ease of transportation

Thermoformed packaging is known for its excellent sealing properties, which eliminates the need for additional buffering or protective materials during transit. This characteristic can reduce packaging preparation time by as much as 25%, allowing for quicker and faster shipping processes.

4. Environmental sustainability

Thermoforming uses fewer raw materials and produces lightweight products; it cuts down on energy consumption during both production and transportation. Additionally, the durability of thermoformed packaging means it can be reused many times. According to industry reports, thermoforming can decrease material waste by 20-40% compared to traditional packaging methods.

5. Durability and protection

Thermoformed trays, made from robust thermoplastic materials, offer superior protection from external damage, rough handling, and environmental factors like moisture, dust, and contaminants. This makes them ideal for industries where product integrity is crucial, such as automotive, pharma and electronics. Industry data indicates that thermoformed packaging can reduce product damage rates by up to 50%, ensuring that goods arrive in pristine condition.

6. Versatility

Whether you need packaging for large, bulky components or small, delicate parts, thermoforming can accommodate a wide range of product specifications — size, thickness, and shape can all be achieved using the same mold. This flexibility ensures that each product gets a perfectly tailored solution. Companies leveraging thermoforming have reported up to a 30% improvement in packaging fit and space utilization compared to standardized packaging solutions.

7. Automation compatibility

Thermoformed packaging is highly compatible with mechanized and automated production and logistics methods, making it an excellent choice for companies using robotics and conveyor systems. This compatibility can enhance workflow efficiency by up to 20%, reducing the risk of human error and ensuring that packaging processes run smoothly and efficiently.