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Thermoform Cups 101: An Introduction to Manufacturing and Materials

Thermoform Cups 101: An Introduction to Manufacturing and Materials

We have been using thermoforming cups in our lives for a long time now. These cups are nothing but a perfect disposable packaging solution that is widely used by the beverage and food industry and even by some non-food application industries. The multiple benefits these thermoforming cups offer make them a perfect choice for top industry players.

Let's understand about thermoforming cups, how they are manufactured, and their applications.

What Are Thermoform Cups?

The PP sheets or HIPS sheets are heated to a certain temperature, where they can be easily bent, folded, twisted, or manipulated. It is then given a specific shape during the manufacturing process using a mould. This process is known as thermoforming. This technique produces disposable items like cups, which are efficient, and cost-effective.

How Thermoform Cups Are Manufactured?

Here are the stages in which a thermoformed cup is manufactured:

1. Sheet Extrusion : The thermoforming process begins with creating a sheet, the building block of the cup. PE or HIPS is extruded from a die into a continuous sheet of the preferred thickness.

2. Thermoforming : The next step is the thermoforming stage. This is where the sheet is heated to a pliable state using radiant ovens/heat lamps. At this stage, the sheet is pressed into a mould cavity to get the preferred cup shape. The pressure and forming time must be controlled to ensure the cup wall thickness is uniform and defects are prevented.

3. Trimming and Stacking : This is the final step, where the extra material around the edges of the cup is trimmed using a die-cutting press. Finally, the finished cups are inspected for quality and stacked for packaging and distribution.

What Materials Are Used for Thermoform Cups?

Let’s take a look at the common materials that are used in the manufacturer process of thermoforming cups:

• Polypropylene (PP): PP displays high strength, is heat resistant and chemically stable, and generally used for cups or containers where sturdiness is required.

• Polyethylene Terephthalate (PET): PET is recyclable, offers outstanding clarity, and has good barrier properties against chemicals and gases. Therefore, it is considered safe for food contact.

• Polystyrene (PS): Polystyrene is a very cost-effective option to go for with good insulation properties.

• High-impact polystyrene (HIPS): HIPS are one of the cost-effective options for various thermoform cups. The cups using these sheets offer good insulation and are suitable for cold beverage/food cups.

We are using the latest technology and manufacturing processes at Cosmo Plastech using PP Sheets and High-Impact Polystyrene (HIPS) sheets to craft thermoform cups. These sheets are known for their versatility and durability and allow us to produce cups that meet industry standards while prioritizing environmental sustainability.

Advantages of Using Cosmo Plastech's Thermoform Cups

The market size of thermoform cups in 2023 was USD 51.96 billion. It is projected to grow to USD 88.50 billion by 2030, exhibiting a CAGR of 7.91% during the forecast period. This increase is due to the multiple advantages thermoform cups offer. These advantages are:

• Affordable : The readily available materials and efficient manufacturing process make thermoform cups a cost-effective packaging solution.

• Durable : Thermoform cups are lightweight but sturdy. They offer good resistance to punctures and tears, too.

• Barrier Properties : With excellent barrier properties against moisture, chemicals, and gases, thermoform cups protect the contents inside from spoiling or contamination.

• Design Flexibility : This process allows customization. The containers or cups are available in a range of shapes, sizes, and colours, catering to diverse needs and branding requirements.

• Printable : The cups are ideal for high-quality printing, which can help you put brand and logos, graphics, and marketing information on the cups.

One must understand the manufacturing process and materials required to make an informed choice regarding thermoform cups. Currently, almost all the industry players are looking for sustainable alternatives to address rising environmental concerns. The future of thermoform cups holds exciting possibilities for innovation and sustainability, and, therefore, this is the right time to partner with us, the best thermoforms cups manufacturers. Connect with us today for more information!

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