Real-World Material Selection Guidance from a PET Sheet Manufacturer
As a PET sheet manufacturer supplying thermoforming-grade materials to food packaging companies for over a decade, we are often asked the same question in different forms:
“Is PET sheet really suitable for my food packaging application — and which PET structure should I choose?”
This article is not written from a marketing department or based on textbook material descriptions. It reflects what we see after thousands of tons of PET sheet have been thermoformed, filled, sealed, shipped, rejected, complained about, and reordered.
We are responsible for material performance after delivery, not just selling rolls.
If your trays crack on the forming line, fog in the display cabinet, or fail seal integrity tests — the problem comes back to us.
This guide focuses on fresh food y ready-to-eat food packaging, specifically:
- Sushi, salads, chilled fresh food
- Cooked meats, ham, and protein trays
- High-speed thermoforming applications
- Export-grade food contact compliance
We will explain where PET works, where it does not, y how to select the correct PET structure based on real production constraints.
1. Why PET Is Chosen for Fresh and Ready-to-Eat Food Packaging — and Why It’s Not Universal
In fresh food and chilled ready-to-eat packaging, Rollos de mascotas are chosen not because they are cheap, but because they offer a balanced combination of:
- High transparency for retail display
- Stable thermoforming behavior at industrial speeds
- Good rigidity at relatively low thickness
- Food-contact safety compliance (FDA / EU)
- Established recycling streams in most regions
However, PET’s advantages only apply within specific processing windows. Misuse leads to cracking, whitening, or sealing failure — issues we see frequently when PET is selected incorrectly.
PET Is Not Chosen When:
- The package must withstand microwave or oven heating
- Continuous exposure above 65–70°C
- Very deep drawing with extreme flexibility
- Ultra-low-cost, low-clarity disposable packaging
Understanding these boundaries is critical.
PET fails when used outside its optimal processing and temperature window, and we see this mistake repeatedly when buyers switch from PP or PS without adjusting expectations.
2. Fresh Food Solutions: Sushi, Salads & Cold Display Packaging
Recommended Materials
APET (Anti-fog optional) & PP (depending on application)
2.1 Why PET (APET) Works for Fresh Food Display
For fresh food such as sushi, salads, fresh fruit, vegetables, and cold deli items, visual appeal directly impacts sales. PET excels here because:
- Transparencia cristalina enhances freshness perception
- High surface gloss improves shelf presentation under LED lighting
- Better rigidity than PP at equal thickness keeps trays flat and stable
In our production lines, APET sheets with 0.35–0.6 mm thickness are the most commonly supplied range for fresh food trays and clamshells.
Typical Thickness Ranges (Fresh Food)
| Solicitud | Common PET Thickness |
|---|---|
| Sushi trays | 0.35–0.5 mm |
| Salad bowls / lids | 0.4–0.6 mm |
| Fruit clamshells | 0.3–0.5 mm |
These thicknesses provide sufficient rigidity while keeping forming temperatures manageable on high-speed thermoformers.
2.2 Anti-Fog PET: When It Is Necessary (and When It Is Not)
Mascota anti-fog is not automatically required.
From real customer feedback:
- Anti-fog is essential when products move from cold storage (0–4°C) to warm retail environments
- Condensation inside the lid reduces visibility and perceived freshness within minutes
Nuestro anti-fog APET sheets are supplied with:
- Cold fog resistance (refrigerated display)
- Optional hot fog resistance (steam exposure during hot filling or reheating under lids)
Important limitation:
Anti-fog coatings can be sensitive to abrasion. If trays are stacked aggressively or transported loosely, performance may degrade. We adjust coating hardness based on logistics conditions — something generic materials do not account for.
2.3 Why PP Is Still Used in Fresh Food (and Where PET Loses)
PP trays are often selected for:
- Lower material cost
- Microwave reheating compatibility
However, PP has trade-offs:
- Lower clarity than PET
- Softer surface — scratches easily
- More difficult forming detail at high speed
In practice, PET is preferred for display-driven fresh food, while PP is chosen when reheating or flexibility matters more than clarity.
3. Ready-to-Eat Packaging: Cooked Meats, Ham & Processed Foods
Recommended Structures
- APET + PE (EVOH optional)
- PP + PE (EVOH optional)
Ready-to-eat (RTE) foods introduce new requirements:
- Heat sealing reliability
- Extended shelf life
- Oxygen and moisture barrier performance
Single-layer PET or PP is often not sufficient.
3.1 Why Composite Structures Are Used
In real production, most RTE packaging failures occur after forming, during sealing or distribution. Composite structures solve this.
APET + PE (EVOH)
This structure is widely used when:
- Clear appearance is still required
- Strong heat sealing to PE lidding film is necessary
Key manufacturing insight:
We supply online thermally laminated APET+PE sheets, not adhesive-bonded ones.
Advantages from production experience:
- No solvent adhesive → safer, more eco-friendly
- Strong peel strength → sealing remains stable after forming
- More consistent thickness control across the roll
EVOH layers are added when:
- Oxygen barrier is critical (e.g., sliced meats, ham)
- Shelf life needs extension beyond standard chilled storage
PP + PE (EVOH)
Chosen when:
- Higher heat resistance is required
- Microwave reheating is expected
Trade-offs:
- Lower transparency than PET
- Slightly softer tray rigidity
- Higher forming temperature window
In our export data, PP+PE is common in Middle East and Southeast Asia, where reheating usage is higher.
4. PET vs PP vs PS: Real-World Selection Logic
4.1 Why PET Is Chosen Over PP or PS (Specific Scenarios)
PET is preferred when:
- Display clarity drives purchasing decisions
- Tray rigidity must remain stable at low thickness
- High-speed forming lines require dimensional consistency
- Recycling infrastructure favors PET (#1)
4.2 Why PET Is NOT Recommended
From real customer issues, PET is not suitable para:
- Microwave heating above ~70–80°C
- Hot-fill applications without modified grades
- Products requiring high flexibility or hinge performance
Common failure symptoms when PET is misused:
- Brittleness and cracking at corners
- Stress whitening during deep draws
- Seal failure due to incompatible lidding films
5. Differences Between APET, RPET, GAG & PETG (Practical View)
Mono
- Best clarity
- Stable forming
- Widely accepted for food contact
- Brittle at low temperatures if over-stretched
RPET
- Sustainable choice
- Slight haze possible depending on PCR quality
- Requires tighter process control
- Accepted in EU & US when compliant
GAG (PET / PETG / PET)
- Better impact resistance
- Mayor costo
- Used for thicker or more complex trays
Petg
- Excellent forming flexibility
- Lower heat resistance
- Used for medical or specialty packaging more than food
6. Processing Behavior on High-Speed Thermoforming Lines
What Buyers Rarely Ask — but Should
6.1 APET Forming Stability
APET offers:
- Amplia ventana de temperatura de formación
- Predictable sag behavior
- Fast cycle times
However:
- Over-drying causes brittleness
- Under-drying causes bubbles and haze
We supply pre-dried sheet when required, especially for export customers with limited drying capability.
6.2 Brittleness: The Most Common Complaint
Brittleness is usually not a PET defect.
It results from:
- Excessive RPET content
- Over-crystallization
- Low forming temperature
- Sharp corner designs
We actively adjust IV levels and impact modifiers based on customer mold geometry.
7. Food Safety, Recycling & Export Considerations
PET is favored internationally because:
- FDA / EU food contact compliance is well established
- PET (#1) recycling streams are mature in US & EU
- RPET content improves brand sustainability metrics
However:
- Multi-layer structures reduce recyclability
- EVOH content must be carefully controlled
We always discuss end-of-life requirements with buyers before recommending material structures.
8. Final Decision Guide: Is PET Right for Your Application?
Choose PET sheet rolls if:
- Your product relies on visual freshness
- You run high-speed thermoforming lines
- Cold or chilled display is required
- Recycling compliance matters
Do NOT choose PET if:
- Microwave or high-heat use is mandatory
- Extreme flexibility is required
- Cost is the only decision factor
9. About DESU PET Sheet Manufacturing
At DESU, we do not sell “standard PET sheets”.
We supply application-specific PET structures, adjusted for:
- Food type
- Forming speed
- Sealing method
- Export destination
If a tray cracks, fogs, or fails sealing — we treat it as our responsibility, not yours.
Our Responsibility as a PET Sheet Supplier
We do not ship “standard PET” and walk away.
Every project involves:
- Application review
- Forming depth analysis
- Sealing compatibility checks
- Logistics and storage consideration
Because when trays fail after delivery, it reflects on the material — not the machine.
