Efficient material handling requires packaging that can protect products, support repeatable handling, and make better use of warehouse and transportation space. Lightweight plastic packaging created through thermoforming operations provide a durable reusable form of packaging that manufacturers, distributors, and logistics programs can rely on for material handling applications.
At Allied Plastics, we design and manufacture custom lightweight plastic packaging solutions using medium to heavy gauge thermoforming. Different shapes can be engineered around your load requirements, equipment, storage environment, handling process, and transportation goals.
Whether you are replacing disposable packaging, reducing return freight, or developing a custom solution for an automated system, our team can help guide the project from initial design through repeat production.
Custom Features and Design Options
We understand that each application has different handling, storage, and protection requirements. Depending on your application, we can evaluate design features such as:
- Draft angles
- Uniform wall thickness
- Rounded corners
- Stackable/nestable geometry
- Ribs
- Snap-fits, hinges, mechanical latches
- Tamper-evidence
- Leak resistance
- Custom cavities
- Textured surfaces
- Branding
- Material selection
Our engineering team can also review the product, material flow, storage conditions, and expected number of reuse cycles before recommending the best material and design.
Common Applications for Thermoformed Lightweight Plastic Packaging
Custom thermoformed packaging can support material handling needs across a wide range of industries and applications, including:
- Food and beverage containers
- Blister packs
- Tamper-proof displays
- Sterile instrument trays
- Device compartments
- ESD-safe trays
- Returnable dunnage and shipping trays
Lightweight packaging applications may also be integrated with lids, sleeve packs, or protective components to create a complete reusable packaging system.
Unique Benefits of Thermoformed Lightweight Plastic Packaging
Space-Efficient Designs
Lightweight packaging can be designed to fit in tight spaces depending upon the application, freeing up warehouse space, high-traffic zones, or other application-pending areas.
Reliable Load Support
Thermoforming provides durability and even in lightweight packaging, the finished component can withstand numerous environmental and work-place considerations.
Lightweight Construction
Thermoformed plastic typically weighs less than comparable metal alternatives and can also reduce the weight associated with other forms of packaging.
Consistent Dimensions
Thermoformed plastic provides repeatable dimensions. This consistency can support smoother handling through conveyors, robotic equipment, automated storage, and general handling applications.
Durability and Reuse
Thermoformed lightweight plastic packaging is also designed for repeated use. They resist moisture, corrosion, and many common environmental conditions, helping reduce replacement frequency and support a lower total cost of ownership.
Custom Engineering
Packaging can be designed around specific products, equipment, weight requirements, and handling processes rather than forcing an application to fit a product that wouldn’t work.
Allied Plastics: Your Trusted Partner From Initial Design to Repeat Production
At Allied Plastics, we support more than the forming process alone. Our team can help evaluate your current packaging products, identify opportunities for improvement, develop a prototype, and refine the design before production.
With engineering, tooling, custom plastic sheet extrusion, heavy-gauge thermoforming, CNC trimming, finishing, assembly, kitting, inventory support, and distribution capabilities, we can simplify the transition from start to finish.
When you are ready to launch your next lightweight plastic packaging project, feel free to share your needs with our team. We will review your request and follow up with the next steps for developing a custom thermoformed packaging solution fit for your application.