Thermoforming Sheet for Food Trays & Clamshells — Not Injection Containers or Films

Direct Conclusion (Short Answer First)

If you are sourcing rigid thermoforming sheet to produce food trays, clamshell boxes, or fresh produce containersو PET sheet is the safer, more compliant, and more sustainable long-term choice.

PVC thermoforming sheet still exists in certain low-cost or legacy applications, but for direct food contact packaging, especially in export markets (US, EU, Japan), PET is overwhelmingly preferred due to:

• Stronger global regulatory acceptance
• No chlorine chemistry
• Better recyclability (PET stream #1)
• Higher clarity for retail display
• Better brand sustainability positioning

From a procurement perspective, PVC may appear slightly cheaper per kg, but when factoring in compliance risk, recycling pressure, and customer requirements, PET typically delivers lower long-term risk and higher market acceptance.

This article reflects 10+ years of hands-on experience supplying thermoforming sheet to food packaging manufacturers across North America, Europe, and Southeast Asia.

1. Understanding the Context: We Are Talking About Thermoforming Sheet

This comparison specifically covers:

• Rigid plastic sheet (roll or cut sheet)
• Used for vacuum forming or pressure forming
• Applied to food trays, fruit boxes, mushroom trays, bakery clamshells
• Thickness range: 0.2mm–1.0mm typical
• Not injection molded solid containers
• Not flexible film packaging

That distinction matters because processing, compliance, and cost structure differ significantly.

2. PET vs PVC Thermoforming Sheet — Technical & Commercial Comparison

عامل	PET Sheet (APET / RPET)	PVC Sheet (Rigid PVC)
امتثال الاتصال الغذائي	Widely approved (FDA, EU 10/2011)	Allowed but under more scrutiny
Chemical Structure	Polyester (no chlorine)	Contains chlorine (PVC = polyvinyl chloride)
Recyclabality	Highly recyclable (#1 stream)	Limited recycling infrastructure
الوضوح البصري	Excellent, glass-like	Good, slight bluish tone
كثافة	~1.33–1.38 g/cm³	~1.38–1.45 g/cm³
Odor	حيادي	Slight odor at high temperature
Processing Temperature	~120–160°C forming range	~140–180°C
Heat Stability	Stable	Risk of HCl release at overheating
Sustainability Perception	Strong	Weak in Western markets
Typical Cost	Slightly higher per kg	Slightly lower per kg

3. Regulatory & Food Safety Considerations

3.1 PET Compliance Strength

PET used in thermoforming sheet is widely compliant with:

• US FDA food contact regulations
• لائحة الاتحاد الأوروبي رقم 10/2011
• Many Asian market standards

It does not contain chlorine or plasticizers in rigid sheet form.

For direct contact with fresh foods like:

• Mushrooms
• الفواكه
• Bakery products
• Ready meals

PET has become the dominant choice globally.

3.2 PVC Regulatory Pressure

PVC itself can be food contact compliant. However:

• It contains chlorine.
• When overheated during forming, it can release HCl gas.
• Disposal concerns exist due to dioxin risks in incineration.
• Many global retail chains discourage PVC packaging.

In my experience, European buyers increasingly reject PVC packaging outright for fresh food applications.

Large retailers in markets like Germany, France, and Scandinavia have already phased it out.

4. Sustainability & Recycling — The Decisive Factor

If you export food packaging products, sustainability is no longer optional.

PET Advantages

• Recyclable under resin code #1
• Strong global recycling stream
• Can be supplied as RPET (30–100% recycled content)
• Accepted in curbside recycling in most developed markets

PVC Limitations

• Very limited recycling channels
• Often treated as contaminant in PET recycling stream
• Chlorine content complicates recycling and incineration
• Increasing ESG pressure against PVC use

For brands seeking ESG reporting compliance, PET is significantly easier to justify.

5. Performance in Thermoforming Applications

5.1 Clarity & Shelf Appeal

PET provides superior clarity and gloss.
For retail display packaging, especially:

• Fresh fruit trays
• Salad boxes
• Bakery clamshells

PET gives a premium appearance that supports price positioning.

PVC clarity is good, but PET generally offers better brilliance and transparency.

5.2 Forming Stability

PET thermoforming sheet offers:

• Stable forming window
• Good wall thickness distribution
• Low odor during forming

يأتي PVC:

• Can form well
• But requires stricter temperature control
• Risk of degradation if overheated

For high-speed automated thermoforming lines, PET is generally more forgiving.

PET Sheet vs. PVC Sheet for Thermoforming Packaging

6. Cost Analysis — What Procurement Teams Really Care About

PVC is often 3–8% cheaper per kg compared to virgin PET in some markets.

However, total cost should include:

1. Compliance documentation
2. Recycling expectations
3. Customer rejection risk
4. Brand sustainability requirements
5. Future regulation risk

Many buyers who initially switch to PVC for cost reasons eventually return to PET due to downstream pressure from clients.

In B2B packaging supply chains, risk cost is often higher than raw material savings.

7. Application Scenario Recommendations

Choose PET If:

• Packaging fresh produce (mushrooms, berries, salads)
• Exporting to US or EU
• Supplying retail supermarket chains
• Brand image matters
• Sustainability reporting is required
• Using recycled content

PVC May Be Considered If:

• Selling to local markets with no sustainability pressure
• Ultra cost-sensitive applications
• Non-export environment
• Short-term packaging projects

However, long-term trend strongly favors PET.

8. Buyer Procurement Decision Framework

When choosing between PET and PVC thermoforming sheet, evaluate:

Final Market Destination

US/EU = PET preferred
Developing domestic market = cost-driven decision possible

Brand Positioning

Premium retail = PET
Low-end commodity packaging = PVC possible

Recycling Requirements

If customer requests recyclable packaging → PET only

Long-Term Regulatory Risk

PVC faces increasing global pressure.

From a strategic procurement standpoint, PET offers future-proofing.

9. Market Trend Data (Industry Observation)

Over the past decade:

• PET share in rigid thermoforming food packaging has continuously increased.
• PVC share has declined in Western markets.
• RPET adoption is accelerating due to circular economy policies.

Several global supermarket groups now require recyclable mono-material packaging — PET fits this requirement, PVC does not.

FAQ Section

Final Professional Recommendation

From over a decade of supplying thermoforming sheet for food packaging:

If your business supplies retail food packaging, exports products, or works with regulated markets, PET is the professional and future-proof choice.

PVC remains a cost-driven alternative in limited scenarios, but its global acceptance is declining.

For serious packaging manufacturers focused on long-term growth, PET thermoforming sheet is the strategic material.