PET vs PVC for Food Packaging
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 containers, 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
| Factor | PET Sheet (APET / RPET) | PVC Sheet (Rigid PVC) |
|---|---|---|
| Food Contact Compliance | Widely approved (FDA, EU 10/2011) | Allowed but under more scrutiny |
| Chemical Structure | Polyester (no chlorine) | Contains chlorine (PVC = polyvinyl chloride) |
| Recyclability | Highly recyclable (#1 stream) | Limited recycling infrastructure |
| Optical Clarity | Excellent, glass-like | Good, slight bluish tone |
| Density | ~1.33–1.38 g/cm³ | ~1.38–1.45 g/cm³ |
| Odor | Neutral | 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
- EU Regulation 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
- Fruits
- 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
PVC sheet:
- Can form well
- But requires stricter temperature control
- Risk of degradation if overheated
For high-speed automated thermoforming lines, PET is generally more forgiving.
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:
- Compliance documentation
- Recycling expectations
- Customer rejection risk
- Brand sustainability requirements
- 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
Q1. Is PVC safe for direct food contact?
Rigid PVC can meet food contact standards, but it faces increasing environmental and regulatory scrutiny compared to PET.
Q2. Why is PET considered more sustainable?
Because PET has an established recycling stream (#1 resin code) and can incorporate recycled content easily.
Q3. Is PET more expensive?
Slightly, but lifecycle cost and compliance benefits often outweigh raw material price difference.
Q4. Which material is better for mushroom trays?
PET is strongly recommended due to food safety perception, clarity, and export compliance.
Q5. Does PVC affect food taste?
If processed properly, no. However, overheating during thermoforming can cause odor issues.
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.
