How Thermoforming Films Are Made? – Process & Applications

As the manufacturer of food items, willing to innovate the packaging of your products? For doing this, thermoforming films have emerged as a cornerstone of innovation. They offer functionality, hygiene, and shelf appeal in a single solution. Bagla Group, a leading packaging solution manufacturer, brings evolution. We deliver high-performance thermoforming films that seal freshness, enhance product visibility, and optimize packaging efficiency. This blog will walk you through how thermoforming films are made in the Bagla Group manufacturing plant. For the packaging buyer, food processor, this will help you to build credibility.

So, just dive into the reading to understand the features, quality, and scientific facts related to the thermoforming films to enhance the food shelf life & freshness.

What Are Thermoforming Films?

Thermoforming films are thin plastic films that are used to package food products. They are heated and molded into specific shapes to form a shape according to the product. At Bagla Group, we design custom-engineered films for use as per the customer’s requirements. To meet the various industry demands, thermoforming films have various quality as vacuum skin packaging, modified atmosphere packaging (MAP), and deep-draw tray sealing.

Thermoforming Films Are Made (Manufacturing Process)

To understand the process of how thermoforming films are made, we have divided these stages into 6 key points.

1. Material Selection & Resin Blending

The journey of the manufacturing of thermoforming films begins with the selection of the right polymers. Depending on the end-use, we may use a single material or co-extrude multiple layers. Common resins include:

• Polyethylene (PE) – Excellent flexibility and sealability
• Polypropylene (PP) – Great for high-clarity applications
• Polyethylene Terephthalate (PET) – Known for strength and recyclability
• Ethylene Vinyl Alcohol (EVOH) – Provides a superior oxygen barrier

At Bagla Group, we work with high-purity, food-safe resins to ensure compliance with international safety standards.

2. Extrusion or Co-Extrusion

Once the selection of the resins is done then they melt the extruded material through flat dies to form a sheet. In this process, multiple resins are layered together to enhance barrier and sealing properties. Our state-of-the-art multi-layer extrusion lines at Bagla Group allow us to create films with multiple layers, each customized for optimal performance.

3. Film Cooling & Thickness Calibration

The hot sheet was rapidly cooled using chill rolls to lock in its properties. This stage will help us to control film thickness uniformity. It is critical to form in packaging lines. Our expert team believes in measuring and monitoring every millimeter through inline quality control systems. This will help to ensure consistent gauge and optical clarity.

4. Corona Treatment & Surface Conditioning

Corona discharge is treated with the films to increase the surface energy, improving printability and adhesion for lidding films. This is necessary for applications where visual impact is key.

5. Slitting & Rewinding

Once the thermoforming films are processed then they are slit into specific widths. Later, they are wound into rolls that fit seamlessly into the automatic thermoforming machines. Bagla Group offers custom roll dimensions and core types to match a wide range of packaging systems used globally.

6. Quality Testing & Packaging

Before dispatch, every batch of thermoforming film undergoes rigorous testing:

• Seal strength
• Oxygen & moisture barrier levels
• Clarity and haze
• Tensile and elongation properties

Only when the film meets our stringent standards is it packed and shipped to customers across continents.

List Of Materials Used in Thermoforming Films

For the best output of the thermoforming films, Bagla Group customizes materials based on functional, mechanical, and regulatory requirements. We use the products as per the common layers and their purpose. The material is as follows:

We also offer recyclable mono-material solutions for customers aiming for eco-friendly packaging.

As we know that currently customers are aiming for eco-friendly packaging, so keeping this in min,d Bagla Group offers recyclable mono-material solutions.

Applications of Thermoforming Films

Bagla Group thermoforming films are widely used in the food and industrial sectors. 

1. Food Packaging

Vacuum Skin Packaging (VSP)

• Ideal for meats, seafood, and cheeses
• Extends shelf life by removing oxygen
• Enhances visual appeal with a “second skin” look

MAP Trays (Modified Atmosphere Packaging)

• Used for ready-to-eat meals and salads
• Modified gas environment maintains freshness and color
• Reduces bacterial growth

Blister Packs & Dessert Cups

• For bakery, confectionery, dairy, and single-serve desserts
• Custom shapes and high-clarity films showcase the product

Dry Food Packaging

• Cereals, grains, and snacks can be packed using deep-draw films
• A high barrier to moisture ensures crunchiness

2. Non-Food Packaging

• Industrial components, tools, and hardware
• Custom inserts, transport trays
• Excellent shock resistance and shape memory

Sustainability in Thermoforming Films

At Bagla Group, we are committed to reducing environmental impact. Some of our sustainability-driven initiatives include:

• Mono-material PE films are compatible with recycling streams
• Lightweighting to reduce plastic usage without compromising strength
• Use of bio-based resins where possible
• Closed-loop production systems for internal waste recycling

Why Leading Brands Trust Bagla Group?

With over three decades of innovation, Bagla Group packaging solution provider, has become a trusted partner to global food brands. Here’s what sets us apart:

• 10 M+ trays sealed annually using our films
• Certified food safety compliance (BRC, ISO, FDA)
• Fast turnaround with tailored solutions
• On-ground technical support to optimize your line’s performance

Whether you’re launching a new product or scaling production, our thermoforming films are engineered to deliver consistency, reliability, and shelf appeal.

Conclusion – Thermoforming Films Are Made

Thermoforming films may seem simple, but they are the result of precision engineering, careful material science, and high-performance design. As consumer expectations rise and sustainability becomes non-negotiable, partnering with a proven expert like Bagla Group can give your brand a competitive edge.

If you’re looking to upgrade your food packaging solutions with safe, reliable, and visually appealing thermoforming films, let’s connect.