Comprehensive Guide to Choosing Thermoforming Materials for Fruit and Vegetable Packaging

Fruit and vegetable packaging plays a crucial role across the entire fresh produce supply chain. Beyond simple containment, packaging influences product freshness, transportation safety, visual presentation, and consumer purchasing decisions. With the widespread adoption of thermoforming technology, selecting the right plastic sheet material—particularly for clamshells, trays, and hinged containers—has become a key factor for produce brands, packaging factories, and exporters.

Among the various thermoforming materials, PET (Polyethylene Terephthalate) and RPET (Recycled PET) have emerged as the dominant choices due to their balance of safety, clarity, strength, and environmental sustainability.

This comprehensive guide provides a detailed comparison of PET, RPET, PP, PS, and PLA, helping you choose the ideal material for fruit and vegetable packaging according to performance, cost, and regulatory considerations.

Before selecting a thermoforming material, it is important to understand the functional needs of fresh produce packaging.

1. Freshness and Breathability

• Condensation control
• Optional ventilation holes for berries and tomatoes
• High-clarity packaging helps consumers evaluate freshness

2. Strength and Stacking Performance

Packaging must withstand:

• Transportation pressure
• Cold-chain logistics
• Long-distance export
• Retail shelf stacking

3. Food-Grade Safety

• BPA-free
• No migration of harmful chemicals
• Approved for direct food contact

4. Branding and Product Display

High transparency and gloss are crucial, especially for:

• Strawberries
• Blueberries
• Grapes
• Cherry tomatoes

5. Global Sustainability Trends

Governments and supermarkets increasingly demand:

• Recyclable materials
• Lower carbon footprint
• Post-consumer recycled content

PET and RPET align well with these requirements, making them the leading choices for modern produce packaging.

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2. RPET (Recycled PET)

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3. GAG (PETG–APET–PETG) Co-extruded Sheets

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4. PP (Polypropylene)

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5. PS (Polystyrene)

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6. PLA (Polylactic Acid)

Advantages:

• Fully biodegradable
• Excellent for eco-label branding

Limitations:

• Higher cost
• Limited heat-resistance and cold-chain performance

Best for: Markets with strict compostable requirements.

(PET / RPET / GAG / PP / PS / PLA)

Material	Transparency	Thermoforming Performance	Impact Strength	Food Safety	Cold-Chain Suitability	Sustainability	Cost Level	Typical Applications
PET	★★★★★ (Excellent)	★★★★☆ (Stable forming, good wall distribution)	★★★★☆	FDA / EU approved	Excellent	Recyclable (rPET stream)	Medium	Berry clamshells, fruit boxes, clear trays
RPET	★★★★☆ (High, slightly gray tone)	★★★★☆	★★★★☆	FDA-grade available	Excellent	High (PCR content, low carbon footprint)	Low–Medium	Export packaging, sustainable fruit containers
GAG (PETG–APET–PETG)	★★★★★ (Crystal clear)	★★★★★ (Deep forming, complex shapes)	★★★★★	Food-grade	Excellent	Recyclable	Medium–High	Premium produce boxes, deep-draw containers
PP	★★☆☆☆ (Low transparency)	★★★☆☆	★★★★☆ (Flexible)	Food-grade	Good	Recyclable	Low	Vegetable trays, microwaveable packaging
PS	★★☆☆☆	★★★☆☆ (Easy forming but brittle)	★★☆☆☆	Declining acceptance	Poor (brittle in cold)	Low (not eco-favored)	Very low	Low-cost trays, limited fruit packaging
PLA	★★★☆☆	★★☆☆☆ (Heat-sensitive)	★★★☆☆	Food-safe	Limited (poor cold-chain resistance)	Biodegradable	High	Compostable packaging, eco markets

PET and RPET offer the ideal balance of performance and sustainability.

1. Superior Transparency and Gloss

High clarity enhances shelf appeal and consumer confidence, especially for berries and premium fruits.

2. Strong Structure and Impact Resistance

Reduces breakage during:

• Harvest handling
• Transportation
• Retail stocking

3. Excellent Cold-Chain Compatibility

PET maintains strength and avoids brittleness even at low temperatures.

4. Widely Recognized Food Safety Standards

Compliant with:

• FDA
• EU No.10/2011
• GB 4806.7-2016

5. Recyclable and Sustainability-Driven

RPET supports:

• Lower carbon emissions
• European PCR requirements
• Supermarket sustainability commitments

PET/RPET is the most future-proof material for produce packaging.

When evaluating PET & RPET suppliers, consider:

1. Transparency & Gloss

Higher clarity = stronger retail impression.

2. Impact Strength & Rigidity

Critical for stacking and transport safety.

3. Thickness Uniformity

Ensures consistent thermoforming results.

4. Food-Grade Certification

The supplier should provide:

• FDA
• EU 10/2011
• Migration test reports

5. Thermoforming Performance

Good heating response, stable wall distribution.

Material	Cost	Transparency	Sustainability	Recommended Use
PET	Medium	★★★★★	Recyclable	Premium clamshells
RPET	Low–Medium	★★★★☆	Recycled material	Export packaging
PP	Low	★★☆☆☆	Recyclable	Vegetable trays
PS	Very low	★★☆☆☆	Declining use	Low-cost packaging
PLA	High	★★★☆☆	Biodegradable	Specialty eco markets

RPET offers the best balance of performance + sustainability + cost.

Regulations worldwide are pushing for recycled content:

• EU: Minimum 25–30% recycled content for packaging
• USA: Several states require 15–20% PCR materials
• Retailers: Walmart, Costco, Tesco, and Carrefour request RPET packaging

PET & RPET align perfectly with these long-term policies.

For Export-Oriented Packaging

✔ RPET (80–100%)
✔ Choose A-grade RPET for high transparency

For Domestic Retail & Cold-Chain

✔ PET or PET/RPET mix

For Cost-Sensitive Applications

✔ PP

For High-End Fruit Gift Boxes

✔ Ultra-clear PET

PET and RPET have become the global standard for fruit and vegetable thermoforming packaging thanks to their unmatched combination of transparency, safety, strength, and recyclability. They meet modern supply-chain demands and support environmental goals, while also being cost-effective and widely accepted by global retailers.

As sustainability regulations continue to tighten worldwide, PET & RPET thermoforming sheets will play an even more critical role in the future of produce packaging.

• Annual production capacity of over 40,000 tons
• Food-grade dust-free workshop
• High-transparency extrusion technology
• Capable of producing PET, RPET, GAG, PETG, PP, and PS/HIPS
• Stable supply chain and fast delivery
• Customizable parameters based on customer’s fruit and vegetable packaging box molds