Thermoformed Plastics: Technologies and Global Markets

• Publication date: May 2012
• Report size: 235 pages

INTRODUCTION REASONS FOR DOING THE STUDY The objective of this study is to provide a comprehensive analysis for those who are interested and/or involved in the plastic thermoformed businesses that include resin producers, plastic sheet producers, thermoformers and those in the major industries using these products. There has, over the last decade, been something of a surge in the use of thermoformed plastic products d...

INTRODUCTION

REASONS FOR DOING THE STUDY

The objective of this study is to provide a comprehensive analysis for those who are interested and/or involved in the plastic thermoformed businesses that include resin producers, plastic sheet producers, thermoformers and those in the major industries using these products. There has, over the last decade, been something of a surge in the use of thermoformed plastic products due to improved technologies, and as a result, thermoformed plastics are competing favorably with injection molding in several key applications.

In addition, there have been very few previous studies that have quantitatively segmented the thermoformed portion of the plastic sheet business, since plastic sheet is the precursor to plastic thermoformed products and is also used extensively without being heated and stretched to plastic thermoformed products. Thermoformed products have also been made from films as well.

SCOPE OF THE STUDY

The focus of the study is to quantify consumption of the major types of plastics used as thermoformed materials into each of its major applications. Thermoformed plastics are involved in several important applications such as rigid food and healthcare packaging, automotive, building products, appliances, and a wide array of consumer and industrial/commercial products. The overall quantitative coverage is global. Market values indicated are at the manufacturer level in 2012 U.S. dollars without adjustment for inflation.

METHODOLOGY AND INFORMATION SOURCES

Both primary and secondary research methodologies were used in preparing this study. Extensive searches were made of the literature regarding thermoformed plastics, including most of the leading trade journals, technical papers, company literature, related government publications and pertinent trade associations.

In addition, key thermoformers and trade publication personnel were contacted in an attempt to verify consumption, company products, key applications and market trends, among other factors.

INTENDED AUDIENCE

Due to the size and diversity of the products used in plastic thermoforming, this report should be of interest to those involved in the development, manufacture, sales and use of these materials. This report will be of value to both technical and business personnel in the following areas among others:

Personnel in end-user companies in a wide range of industries from food and healthcare packaging along with those in the automotive, building product and other industries.
Marketing, technical and management personnel in companies that produce, market and sell thermoformed plastics and plastic sheet.
Companies that produce the key plastic materials that are converted into thermoformed products.
Personnel in government at several levels, ranging from federal to state and local authorities, many of whom are involved in trying to ensure public health and safety.
Financial institutions such as banks, venture capitalists and others.

ABOUT THE AUTHOR

Research analyst Mel Schlechter has more than 40 years of experience in the chemical industry, and specializes in plastics market research. He has been with BCC Research for more than 10 years and holds a B.S. in chemistry, a M.S. in organic chemistry and a M.B.A. in marketing.

Global Plastic Industry

TABLE OF CONTENTS

CHAPTER ONE: INTRODUCTION 1
REASONS FOR DOING THE STUDY 1
SCOPE OF THE STUDY 1
METHODOLOGY AND INFORMATION SOURCES 1
INTENDED AUDIENCE 2
ABOUT THE AUTHOR 2
RELATED BCC REPORTS 2
BCC ONLINE SERVICES 3
DISCLAIMER 3
CHAPTER TWO: SUMMARY 4
SUMMARY TABLE GLOBAL THERMOFORMED PLASTIC MARKET
BY APPLICATION, THROUGH 2017 (MILLION POUNDS) 4
SUMMARY FIGURE GLOBAL THERMOFORMED PLASTIC MARKET
BY APPLICATION, THROUGH 2017 (MILLION POUNDS) 5
CHAPTER THREE: PLASTIC SHEET 6
HISTORY 6
BACKGROUND 6
DEFINITIONS 6
PLASTIC SHEET OVERVIEW 7
OTHER CONSIDERATIONS 7
SHEET EXTRUSION 7
OVERVIEW 7
MARKETS 8
TABLE 1 LEADING U S PLASTIC SHEET PRODUCERS, 2011 SALES
($ MILLIONS) 9
CHAPTER FOUR: THERMOFORMING 10
HISTORY 10
OVERVIEW 10
ADVANTAGES 10
BASIC STEPS OF THERMOFORMING 11
TECHNOLOGY 11
OVERVIEW 11
MACHINERY 12
MOLD DESIGN 12
MOLDING MATERIALS 13
Overview 13
Details 13
DETERMINING THE RIGHT TEMPERATURE FOR
THERMOFORMING 13
CONTROLLING SHEET SAG 14
OTHER POTENTIAL PROBLEMS 14
THERMOFORMING PROCESSES 14
Overview 14
More Specific Technical Advantages 15
Thermoform/Fill/Seal (TFS) Packaging 15
Vacuum Forming 16
Pressure Forming 16
Thin- and Thick-gauge Thermoforming 17
Twin-sheet Thermoforming 18
Engineering Aspects 19
Roll Goods Manufacture 19
Other Production Variables 19
Issue of Scrap Removal 20
Other Factors 20
THERMOFORMING EQUIPMENT 20
In-line Equipment 20
Shuttle Thermoformers 21
Rotary Thermoformers 21
BROAD OVERVIEW APPLICATIONS OF THERMOFORMED
PLASTICS 21
TABLE 2 SELECTED EXAMPLES OF PLASTIC THERMOFORMED
PRODUCTS BY MAJOR APPLICATIONS 22
THERMOFORMABLE POLYMERS 22
OVERVIEW 22
STYRENICS 23
POLYPROPYLENE 23
POLYETHYLENES 24
POLYESTERS 24
PVC 24
ABS 24
ACRYLICS 25
POLYCARBONATES 25
ADVANTAGES AND DISADVANTAGES OF KEY
THERMOFORMABLE POLYMERS 25
TABLE 3 ADVANTAGES AND DISADVANTAGES OF SELECTED
THERMOFORMABLE POLYMERS 25
TABLE 3 (CONTINUED) 26
CHAPTER FIVE: DETAILS ON RESINS USED IN THERMOFORMING 27
OVERVIEW 27
POLYSTYRENE 27
BACKGROUND 27
GENERAL PURPOSE POLYSTYRENE 27
Background 27
Characteristics 27
HIGH IMPACT POLYSTYRENE (HIPS) 28
Background 28
Properties 28
Applications 28
STYRENIC POLYMER PRODUCER SCENARIO 29
Overview 29
The New North American Styrenic Scenario 30
PROCESSING 30
Overview 30
TABLE 4 FABRICATION METHODS AND USES FOR POLYSTYRENE 30
Injection Molding 30
Extrusion of Styrene Polymers 31
Overview 31
Coextrusion 31
THERMOFORMING OF STYRENE POLYMERS 31
ORIENTED POLYSTYRENE SHEET (OPS) 32
Background 32
Properties 32
Technology 33
Advantages of OPS 33
Major Applications 33
TYPICAL POLYSTYRENE RIGID FOOD PACKAGING
APPLICATIONS 34
Background 34
Thermoforming Processing 34
OPS Rigid Food Packaging Applications 34
KEY POLYSTYRENE THERMOFORMERS 35
TABLE 5 KEY NORTH AMERICAN POLYSTYRENE
THERMOFORMERS 35
POLYPROPYLENE 36
BACKGROUND 36
OVERVIEW 36
PRODUCERS AND CAPACITIES 37
TABLE 6 LEADING GLOBAL POLYPROPYLENE PRODUCERS
(BILLION LBS ) 37
PROPERTIES 38
Background 38
Polypropylene Property Advances 38
TYPICAL APPLICATIONS 39
THERMOFORMED POLYPROPYLENE 39
POLYPROPYLENE FOOD PACKAGING APPLICATIONS 39
POLYPROPYLENE THERMOFORMERS 40
TABLE 7 LEADING NORTH AMERICAN POLYPROPYLENE
THERMOFORMERS 40
NEW DEVELOPMENTS 40
Formosa Plastics 40
ConocoPhillips Activities 41
Braskem (Brazil) 41
Other Changes 41
THERMOPLASTIC OLEFINS (TPOS) 41
OVERVIEW 41
GENERAL APPLICATIONS 42
THERMOFORMING OF TPOS 42
Background 42
RECENT DEVELOPMENTS 43
Unfilled TPOs for Large Thermoformed Parts 43
LyondellBasell New Products 43
ExxonMobil New Grades 43
Spartech Activities 43
POLYETHYLENES 44
BACKGROUND 44
HIGH DENSITY POLYETHYLENE (HDPE) 44
Overview 44
Background 44
HDPE Thermoformed Products 45
TABLE 8 EXAMPLES OF THERMOFORMED HDPE PRODUCTS 45
Examples of Thermoformed HDPE Products 45
CP Chem 45
Sabic Europe 46
Formosa Plastics 46
Recycling Aspects 46
LOW DENSITY POLYETHYLENE (LDPE) 46
Overview 46
Properties 47
Markets and Applications 47
Producers 47
TABLE 9 GLOBAL LDPE PRODUCERS AND LOCATIONS 47
TABLE 9 (CONTINUED) 48
POLYETHYLENE THERMOFORMERS 48
TABLE 10 LEADING U S POLYETHYLENE THERMOFORMERS 48
POLYESTERS 49
BACKGROUND 49
OVERVIEW 49
MAJOR APPLICATIONS 49
MODIFIED PET RESINS 49
Background 49
APET 50
CPET 50
Glycol-modified PET Copolyester (PETG) 50
PRODUCERS AND CAPACITIES 51
NEW PET PRODUCER DEVELOPMENTS 51
Indorama Bought Several Eastman Units 51
Japanese Firms Merge their Respective PET Businesses 52
DAK Americas Completed the Eastman Withdrawal from
the PET Business 52
DAK Americas Also Purchased Wellman’s PET Business 52
M&G Group is Planning a new PET Plant 52
ADVANTAGEOUS PROPERTIES OF THERMOFORMED PET 52
RECENT PET THERMOFORMING DEVELOPMENTS 53
PET Sheet Thermoformed into Clear, Tough Containers 53
PET is Tough to Trim 53
Par-Pak Expands PET Thermoformed Packaging 53
New Environmental Mandates 53
Recycled PET Thermoformed Packaging 54
Thermoformed PET Recycling 54
PET Thermoformed Bales 54
PET THERMOFORMERS 54
TABLE 11 KEY NORTH AMERICAN PET THERMOFORMERS 55
POLYBUTYLENE TEREPHTHALATE (PBT) 55
Background 55
Properties 55
Applications 56
Producers 56
Thermoformable PBT Arrives 56
POLYVINYL CHLORIDE (PVC) 57
OVERVIEW 57
FORMS OF PVC 57
A VERSATILE RESIN 57
PROCESSING 58
Background 58
Extrusion 58
Calendaring 58
TABLE 12 RIGID PVC APPLICATIONS 59
PRODUCERS 59
TABLE 13 GLOBAL PVC PRODUCERS 59
ENVIRONMENTAL ISSUES 60
Positive 60
Negative 60
THERMOFORMED APPLICATIONS 61
PVC THERMOFORMERS 61
TABLE 14 KEY PVC THERMOFORMERS 61
NEW DEVELOPMENTS 61
Thermoformed PVC Tubing 61
Thermoformed PVC in Sport/Leisure Equipment 62
Thermoformable Paper Replaces PVC 62
ACRYLONITRILE-BUTADIENE-STYRENE (ABS) 62
OVERVIEW 62
BACKGROUND 62
PROPERTIES 63
PROCESSING 63
PRODUCERS 64
GENERAL GRADES 64
APPLICATIONS 64
MORE SPECIFIC THERMOFORMED ABS APPLICATIONS 65
ABS THERMOFORMERS 65
TABLE 15 KEY ABS THERMOFORMERS 66
ACRYLICS 66
BACKGROUND 66
PROPERTIES 66
Background 66
Properties of Acrylic Molded, Extruded and
Thermoformed Products 67
ACRYLIC SHEET 67
Manufacturing Methods 67
Properties 68
Examples of Sheet Products 68
TABLE 16 EXAMPLES OF ACRYLIC THERMOFORMED PRODUCTS 68
KEY TRADE NAMED POLYACRYLATES 68
THERMOFORMED POLYACRYLATES 69
ACRYLIC THERMOFORMERS 69
TABLE 17 KEY ACRYLIC THERMOFORMERS 69
TABLE 17 (CONTINUED) 70
POLYCARBONATES 70
OVERVIEW 70
PROCESSING 70
PROPERTIES 70
PROPERTY ADVANTAGES AND DISADVANTAGES 71
TYPES OF POLYCARBONATES AVAILABLE 71
ALLOYS/BLENDS 72
IMPACT OF BISPHENOL A ON POLYCARBONATE USAGE 72
SOME TECHNOLOGIES INVOLVED IN POLYCARBONATE
THERMOFORMING 72
PRODUCERS AND CAPACITIES 72
Producers and Capacities (Continued) 73
TABLE 18 MAJOR POLYCARBONATE PRODUCERS AND TRADE
NAMED PRODUCTS 74
POLYCARBONATE THERMOFORMERS 74
TABLE 19 KEY NORTH AMERICAN POLYCARBONATE
THERMOFORMERS 74
EXAMPLES OF THERMOFORMED POLYCARBONATE
PRODUCTS 75
Thermoformed Polycarbonates in Sign Faces 75
Carriers and Trays for Electronic Assembly 75
Automotive Windshields 75
STYRENE COPOLYMERS 76
OVERVIEW 76
STYRENE BLOCK COPOLYMERS 76
Properties 76
Processing 77
TABLE 20 SBC MAJOR PRODUCTS SEGMENTED BY POLYMER
PROCESS 77
TABLE 20 (CONTINUED) 78
Producers 78
Thermoforming 78
STYRENE ACRYLONITRILE (SAN) 78
ACRYLIC- STYRENE-ACRYLONITRILE (ASA) 79
BIODEGRADABLE POLYMERS 80
OVERVIEW 80
POLYLACTIC ACID 80
Background 80
Thermoformed Packaging 81
Producers 81
Early Work with PLA Thermoforming 82
NatureWork’s Activities 82
Cereplast 83
OTHER THERMOFORMED BIODEGRADABLE RESINS 83
MIXTURES OF STARCH AND BIODEGRADABLE
POLYMERS 83
Background 83
Producers 84
Novamont 84
TABLE 21 TYPES OF PRODUCTS MADE WITH MATER-BI 85
THERMOFORMED TRAYS 85
PLA THERMOFORMERS 86
TABLE 22 KEY PLA THERMOFORMERS 86
RECENT DEVELOPMENTS 86
NatureWorks PLA Polymer 2100D 86
Spartech’s Rejuven 8 and Rejuven 8+ 86
Upgrading Heat Resistance of PLA in Thermoformed
Packaging 86
Biodegradable Thermoformed Food Packaging 87
Modified PLA Trays with DuPont Additive 87
Heat-deflection Temperature Modifier 87
Stonyfield Farm Uses PLA for Yogurt Multipacks 88
OTHER RESINS 88
OVERVIEW 88
NYLONS 88
Overview 88
Major Types 89
Nylon 66 89
Nylon 6 89
Producers 89
POLYPHENYLENE SULFIDE (PPS) 90
Background 90
Thermoformed Polyphenylene Sulfides 90
Producers 91
POLYPHENYLENE OXIDE (PPO)-BASED ALLOYS/BLENDS 92
Overview 92
PPO/HIPS 92
PPO/Nylon 92
Grades and Applications 93
PC/ABS 93
CYCLIC OLEFIN COPOLYMERS (COCS) 94
RECENT DEVELOPMENTS 95
Thermoformable PPS Sheet 95
New Thermoformable Nylon 6 95
Bayer’s Bayblend FR 3030 95
COC Advances 95
A New Noryl Product 95
MARKET ESTIMATES AND FORECASTS 96
TABLE 23 GLOBAL THERMOFORMED PLASTIC MARKET BY RESIN,
THROUGH 2017 (MILLION POUNDS) 97
TABLE 24 GLOBAL THERMOFORMED POLYSTYRENE/HIPS
MARKET BY APPLICATION, THROUGH 2017 (MILLION POUNDS) 98
TABLE 25 GLOBAL THERMOFORMED POLYSTYRENE/HIPS
PACKAGING MARKET BY SEGMENT, THROUGH 2017 (MILLION
POUNDS) 98
TABLE 26 GLOBAL THERMOFORMED POLYSTYRENE/HIPS
BUILDING PRODUCTS MARKET BY SEGMENT, THROUGH 2017
(MILLION POUNDS) 99
TABLE 27 GLOBAL THERMOFORMED POLYPROPYLENE MARKET
BY APPLICATION, THROUGH 2017 (MILLION POUNDS) 99
TABLE 28 GLOBAL THERMOFORMED POLYPROPYLENE
PACKAGING MARKET BY SEGMENT, THROUGH 2017 (MILLION
POUNDS) 100
TABLE 29 GLOBAL THERMOFORMED POLYPROPYLENE BUILDING
PRODUCTS MARKET BY SEGMENT, THROUGH 2017 (MILLION
POUNDS) 100
TABLE 30 GLOBAL THERMOFORMED HIGH-DENSITY
POLYETHYLENE MARKET BY APPLICATION, THROUGH 2017
(MILLION POUNDS) 101
TABLE 31 GLOBAL THERMOFORMED HIGH-DENSITY
POLYETHYLENE PACKAGING MARKET BY SEGMENT,
THROUGH 2017 (MILLION POUNDS) 101
TABLE 32 GLOBAL THERMOFORMED POLYESTER MARKET BY
APPLICATION, THROUGH 2017 (MILLION POUNDS) 102
TABLE 33 GLOBAL THERMOFORMED POLYESTER PACKAGING
MARKET BY SEGMENT, THROUGH 2017 (MILLION POUNDS) 102
TABLE 34 GLOBAL THERMOFORMED PVC MARKET BY
APPLICATION, THROUGH 2017 (MILLION POUNDS) 103
TABLE 35 GLOBAL THERMOFORMED PVC PACKAGING MARKET
BY SEGMENT, THROUGH 2017 (MILLION POUNDS) 104
TABLE 36 GLOBAL THERMOFORMED PVC BUILDING PRODUCTS
MARKET BY SEGMENT, THROUGH 2017 (MILLION POUNDS) 104
TABLE 37 GLOBAL THERMOFORMED ABS MARKET BY
APPLICATION, THROUGH 2017 (MILLION POUNDS) 105
TABLE 38 GLOBAL THERMOFORMED LOW-DENSITY
POLYETHYLENE MARKET BY APPLICATION, THROUGH 2017
(MILLION POUNDS) 105
TABLE 39 GLOBAL THERMOFORMED POLYACRYLATE MARKET BY
APPLICATION, THROUGH 2017 (MILLION POUNDS) 106
TABLE 40 GLOBAL THERMOFORMED POLYACRYLATE BUILDING
PRODUCTS MARKET BY SEGMENT, THROUGH 2017 (MILLION
POUNDS) 106
TABLE 41 GLOBAL THERMOFORMED POLYACRYLATE PACKAGING
MARKET BY SEGMENT, THROUGH 2017 (MILLION POUNDS) 107
TABLE 42 GLOBAL THERMOFORMED POLYCARBONATE MARKET
BY APPLICATION, THROUGH 2017 (MILLION POUNDS) 107
TABLE 43 GLOBAL THERMOFORMED POLYCARBONATE
BUILDING PRODUCTS MARKET BY SEGMENT, THROUGH 2017
(MILLION POUNDS) 108
TABLE 44 THERMOFORMED OTHER RESIN MARKET BY
APPLICATION, THROUGH 2017 (MILLION POUNDS) 108
TABLE 45 THERMOFORMED OTHER RESIN PACKAGING MARKET
BY SEGMENT, THROUGH 2017 (MILLION POUNDS) 109
CHAPTER SIX: APPLICATIONS 110
OVERVIEW 110
APPLICATIONS OF THERMOFORMED PLASTICS 110
RIGID PACKAGING 111
FOOD PACKAGING 111
BACKGROUND 111
ADDITIONAL DETAILS 112
THERMOFORMED FOOD PACKAGING 113
MATERIALS COMPETING WITH PLASTICS IN RIGID FOOD
PACKAGING 114
TABLE 46 OVERVIEW OF MATERIALS COMPETING WITH PLASTICS
IN RIGID FOOD PACKAGING 115
MATERIALS USED FOR THERMOFORMED FOOD
PACKAGING 115
TABLE 47 PLASTICS USED FOR THERMOFORMED FOOD
PACKAGING 115
THERMOFORMED RESIN USAGE 116
CHARACTERISTICS OF THERMOFORMED PLASTIC FOOD
CONTAINERS 116
FOODSERVICE PACKAGING MARKETS 116
Overview 116
Plastic Usage 117
CHARACTERISTICS OF THERMOFORMED FOOD
CONTAINERS 117
Characteristics of …(Continued) 118
PREPARED FOOD CONTAINERS 119
DUAL-OVENABLE AND MICROWAVE FOOD PACKAGING 119
Background 119
Materials Used 119
Packaging Structure Details 120
“Microwave-only” Food Packaging Structures 120
THERMOFORMED PACKAGING OF SPECIFIC FOOD
PRODUCTS 121
Meat/Deli Foods 121
Dairy Products 122
Background 122
Types of Dairy Packaging 123
Clamshell Packaging 124
Frozen Food Packaging 124
Overview 124
Type of Containers 124
Rigid 124
Non-rigid 124
Container Sealing 125
Summary of Thermoformed Products in Rigid Food
Packaging 125
Industry Comments on the Competitive Polymer Scenario
in Rigid Food Packaging 125
HEALTHCARE PACKAGING 126
OVERVIEW 126
DRUG REGULATIONS AND REVIEW PROCESSES 126
HEALTHCARE PACKAGING STANDARDS 127
Compliance with Standards 127
HEALTHCARE PACKAGING SEGMENTATION 127
Overview 127
Background 128
Compliance Packaging 128
Child-resistant/Senior-friendly Healthcare Packaging 128
Overview 128
Some Details 129
Tamper-Evident Healthcare Packaging 129
FACTORS AFFECTING CHOICES OF HEALTHCARE
PACKAGING MATERIALS 130
COMPETING PACKAGING MATERIALS 131
DISPOSABILITY AND RECYCLABILITY 131
RIGID VS FLEXIBLE HEALTHCARE PACKAGING 132
STERILIZATION TECHNIQUES 133
Overview of Methods 133
MEDICAL PACKAGING 133
Overview 133
Packaging Choices 134
Applications 135
Kits 136
Overview 136
Performance Criteria 136
TABLE 48 MATERIAL PROPERTY CRITERIA¾DISPOSABLE KITS 137
Trays 137
Background 137
Property Parameters for Choosing Tray Materials 138
Sterilization 138
Thermoform or Injection Mold? 138
TABLE 49 RESIN PROPERTY CRITERIA ¾ TRAYS 139
Property Parameters for Choosing Tray Materials 139
Tray Designs for Different Environments 140
PHARMACEUTICAL PACKAGING 140
Overview 140
Prescription Pharmaceuticals 140
Non-prescription (OTC) Products 141
Packaging OTC Products 141
Hospital Products/Medical Supplies 142
Containers 142
Closures 143
Blister Packaging 143
Overview 143
Advantages 144
Obstacles 145
Blister Pack Materials 145
Other Important Issues 145
More Details on Resin Choices 146
Some Technologies and Applications 146
TABLE 50 PROS AND CONS OF PHARMACEUTICAL BLISTER
PACKAGING 147
ELECTRONIC PACKAGING 147
OVERVIEW 147
SOME TECHNICAL ISSUES 148
TYPES OF ELECTRONIC PACKAGING 148
Overview 148
Trays 149
Clamshells 149
Blister Packs 149
Displays 149
AUTOMOTIVE 149
OVERVIEW 149
TABLE 51 HISTORICAL, CURRENT AND PROJECTED U S
AUTOMOTIVE SALES, 1997-2017 (MILLION UNITS) 150
TABLE 52 ESTIMATED HYBRID SALES FOR THE U S , 2008-2017
(THOUSAND UNITS) 150
CAFE ISSUES 150
BACKGROUND 151
EXTERIORS 152
Overview 152
Injection/Compression Molding vs Thermoforming 152
THERMOFORMED PLASTIC GAS TANKS 153
Overview 153
Thermoformed vs Multilayer Extrusion 154
California’s Air Resources Board (CARB) Activities and
Results 154
BUILDING PRODUCTS 155
OVERVIEW 155
LIGHTING PRODUCTS 156
Background 156
Type of Lighting Products 156
Resins Used 156
SIGNS/DISPLAYS 157
Background 157
Outdoor Sign Market 158
A New Development 158
APPLIANCES 158
OVERVIEW 158
PLASTICS USAGE 159
TABLE 53 SELECTED MAJOR APPLICATIONS FOR POLYMERS IN
APPLIANCES 159
TRANSPARENT APPLIANCES PARTS 160
Overview 160
Refrigerators 160
Background 160
Door Lids 161
AIRCRAFT 161
OVERVIEW 161
PRODUCTS 161
AS ONE EXAMPLE 161
ITEMS OF INTEREST REGARDING THERMOFORMED
PRODUCTS 162
Thermoformed ABS for Aircraft Cabin Components 162
Aircraft Engine Covers 162
Meeting FAA Standards 162
Aircraft Thermoformed Components 162
Extended Usage of Thermoformed Plastics in Aircraft 162
DuPont Products 163
Sabic IP’s Ultem Composite Thermoformed for Aerospace
Board 163
Advanced Polycarbonates for Aircraft Interiors 163
PALLETS 163
OVERVIEW 163
PLASTIC PROCESSES 164
PALLET TYPES 164
MATERIALS AND DEMAND 164
LAWN/GARDEN EQUIPMENT 165
OVERVIEW 165
SPECIFIC RESIN USAGE 165
SPARTECH THERMOFORMING ACTIVITIES IN
LAWN/GARDEN EQUIPMENT 166
SPORT/RECREATIONAL EQUIPMENT 166
BACKGROUND 166
REQUIREMENTS 167
MARINE 167
OVERVIEW 167
EXAMPLES OF PRODUCTS 167
OTHER CONSUMER PRODUCTS 168
PERSONNEL CARE PACKAGING 168
TABLEWARE 168
INDUSTRIAL/CONSUMER HANDLING TRAYS 168
TOYS 168
MARKET ESTIMATES AND FORECASTS 169
TABLE 54 GLOBAL THERMOFORMED PLASTIC MARKET BY
APPLICATION, THROUGH 2017 (MILLION POUNDS) 170
TABLE 55 GLOBAL THERMOFORMED PLASTIC PACKAGING
MARKET BY SEGMENT, THROUGH 2017 (MILLION POUNDS) 171
TABLE 56 GLOBAL THERMOFORMED PLASTIC BUILDING
PRODUCTS MARKET BY SEGMENT, THROUGH 2017 (MILLION
POUNDS) 171
TABLE 57 GLOBAL THERMOFORMED PLASTIC PACKAGING
MARKET BY RESIN, THROUGH 2017 (MILLION POUNDS) 172
TABLE 58 GLOBAL THERMOFORMED PLASTIC FOOD PACKAGING
MARKET BY RESIN, THROUGH 2017 (MILLION POUNDS) 172
TABLE 59 GLOBAL THERMOFORMED PLASTIC HEALTHCARE
PACKAGING MARKET BY RESIN, THROUGH 2017 (MILLION
POUNDS) 173
TABLE 60 GLOBAL THERMOFORMED PLASTIC ELECTRONIC
PACKAGING MARKET BY RESIN, THROUGH 2017 (MILLION
POUNDS) 174
TABLE 61 GLOBAL THERMOFORMED PLASTIC APPLIANCE
MARKET BY RESIN, THROUGH 2017 (MILLION POUNDS) 174
TABLE 62 GLOBAL THERMOFORMED PLASTIC BUILDING
PRODUCTS MARKET BY RESIN, THROUGH 2017 (MILLION
POUNDS) 175
TABLE 63 GLOBAL THERMOFORMED PLASTIC SIGNS/DISPLAY
MARKET BY RESIN, THROUGH 2017 (MILLION POUNDS) 176
TABLE 64 GLOBAL THERMOFORMED PLASTIC LIGHTING MARKET
BY RESIN, THROUGH 2017 (MILLION POUNDS) 176
TABLE 65 GLOBAL THERMOFORMED PLASTIC OTHER BUILDING
PRODUCT MARKET BY RESIN, THROUGH 2017 (MILLION
POUNDS) 177
TABLE 66 GLOBAL THERMOFORMED PLASTIC AUTOMOTIVE
MARKET BY RESIN, THROUGH 2017 (MILLION POUNDS) 177
TABLE 67 GLOBAL THERMOFORMED PLASTIC AIRCRAFT
MARKET BY RESIN, THROUGH 2017 (MILLION POUNDS) 178
TABLE 68 GLOBAL THERMOFORMED PLASTIC COMMERCIAL
PRODUCT MARKET BY RESIN, THROUGH 2017 (MILLION
POUNDS) 179
TABLE 69 GLOBAL THERMOFORMED PLASTIC CONSUMER
MARKET BY RESIN, THROUGH 2017 (MILLION POUNDS) 179
CHAPTER SEVEN: CLAMSHELLS AND BLISTER PACKS 180
BACKGROUND 180
CLAMSHELLS 180
OVERVIEW 180
ADVANTAGES 180
TYPES OF CLAMSHELLS 181
SEALING OF CLAMSHELLS 181
TABLE 70 SEALING CLAMSHELLS PARAMETERS 181
CLAMSHELL MATERIALS 181
INSERT CARDS 181
BLISTER PACKS 182
BACKGROUND 182
MATERIALS PACKAGED 182
BLISTER PACKS CAN BE MADE VIA THERMOFORMING OR
COLD FORMING 182
IS THERE A DIFFERENCE? 183
NEW DEVELOPMENTS 183
Polyesters Expand for Blister Packaging 183
Blister Pack vs Bottles in the Pharmaceutical Industry 184
Blister Pack Trends 184
CHAPTER EIGHT: THIN-WALLING 185
INTRODUCTION 185
THERMOFORMING THIN-WALLED CONTAINERS 185
CHAPTER NINE: RECENT PLASTIC THERMOFORMING
DEVELOPMENTS 186
OVERVIEW 186
INDUSTRY STRUCTURE 186
UNCERTAINTIES 186
POSSIBLE FUTURE TRENDS 186
NEW THERMOFORMING CENTER 186
GREEN PACKAGING 187
IN-MOLD LABELING 187
20TH ANNUAL THERMOFORMING CONFERENCE
SPONSORED BY THE SAE 187
TECHNOLOGIES 188
THERMOFORMABLE FOAMS 188
USE OF OXYGEN SCAVENGER KEEPS LUNCH FRESH IN
THERMOFORMED CONTAINERS 188
NEGATIVE THERMOFORMING 188
THERMOFORMING GAINS IN THIN-WALLED PACKAGING 189
ADDITIVE RESIN IMPROVES THERMOFORMING
PROCESSING 189
OPTIMIZING SHEET EXTRUSION 190
THERMOFORMED POLYPROPYLENE UPGRADES WITH
NEW NUCLEATOR 190
GREEN AND MICROWAVEABLE 190
HIGHLIGHTS FROM RECENT SPE EUROPEAN
THERMOFORMING CONFERENCE 190
THERMOFORMED GROW TRAYS 191
PRESSURE AND TWIN-SHEET FORMING ARE
INCREASING 191
INCREASED INTEREST IN LARGE PART
THERMOFORMING 192
MARKETS 192
EMERGING MARKETS IN THERMOFORMING 192
PAINT AND DECORATIVE FILMS 192
COMPUTERS HELP THERMOFORMERS 193
RESIN USAGE 193
POLYSTYRENE SHEET DERIVED FROM RECYCLATE 193
RECYCLING ISSUES 193
PROCESSING BIOPOLYMERS FOR RIGID SHEET AND
THERMOFORMING 193
AT&T AND SUGARCANE-BASED THERMOFORMED
PACKAGING 194
CHAPTER TEN: PRICING 195
TABLE 71 PUBLISHED LIST PRICES FOR RESINS USED IN
THERMOFORMING (DOLLARS/POUND) 195
CHAPTER ELEVEN: LEADING PLASTIC THERMOFORMERS 196
PLASTIC THERMOFORMERS 196
TABLE 72 SELECTED KEY THERMOFORMERS ($ MILLIONS) 196
CHAPTER TWELVE: SELECTED PLASTIC THERMOFORMER
CORPORATE ACTIVITIES 197
OVERVIEW 197
BERRY PLANS EXPANSION 197
THERMOFORMERS PENDA AND DURAKON JOIN FORCES 197
PACTIV BUYS A THERMOFORMING PLANT 198
ASSOCIATED PACKAGING TECHNOLOGIES EXPANDS
PACKAGING TRAY CAPACITY 198
PRENT EXPANDING OPERATIONS IN EUROPE AND CHINA 198
PENDA CLOSES A BEDLINER LINE 198
TEK PAK INC OPENS R&D UNIT 199
THERMOFORMER IN-LINE PLASTICS OPENS GEORGIA PLANT 199
PLASKOLITE BUYS OPTIGLASS UNIT 199
TPC PARTNERS NEW MAJORITY OWNER OF TRAY-PAK 199
THERMOFORMER PAR-PAK INCREASES ITS RECYCLING 200
THERMOFORMER MAYFIELD ADDS LINE 200
TAMPER-RESISTANT THERMOFORMED FOOD PACKAGING 200
SPARTECH OPENS NEW TECHNICAL CENTER 200
PACTIV BUYS PWP INDUSTRIES 201
SONOCO BUYS ASSOCIATED PACKAGING TECHNOLOGIES 201
HART’S RANK GROUP BUYS PACTIV 201
PACTIV CLOSES POLYSTYRENE PLANT 201
THERMOFORMER PLASTIQUE ADDS CAPACITY 202
ALVAC PLASTICS ACQUIRED 202
PLASTIKON BUILDING ANOTHER THERMOFORMING PLANT 202
PACTIV TO CLOSE SEVERAL PLANTS 202
PLACON BUYS THERMOFORMER 202
PACTIV MAY BUILD PLANT IN MEXICO 203
POLO CUSTOM PRODUCTS INCREASES THERMOFORMING 203
MULLINEX PACKAGES ACQUIRED BY PRIVATE EQUITY FIRM 203
THERMOFORMER PRENT EXPANDING 203
ROHRER CORPORATION ACQUIRES BUCKELL PLASTICS 203
DART CONTAINER CORPORATION ACQUIRES SOLO CUP
COMPANY 204
CHAPTER THIRTEEN: LEGISLATIVE/REGULATORY AND
ENVIRONMENTAL ISSUES 205
OVERVIEW 205
FOOD PACKAGING 205
THE FOOD AND DRUG ADMINISTRATION (FDA) 205
Background 205
Food Additive Rules and Categories 206
Regulation of Packaging Materials 206
HEALTHCARE PACKAGING 207
DRUG REGULATIONS AND REVIEW PROCESS 208
PACKAGING PLASTICS APPROVAL PROCESS 208
OTHER AGENCIES IMPACTING THE HEALTHCARE
PACKAGING INDUSTRY 209
The Healthcare Compliance Packaging Council (HCPC) 209
RECENT DEVELOPMENTS 209
Efforts Continue for Effective Thermoformed PET
Recycling 209
New Program Launched 210
Review of Styrene Safety Decision 210
CHAPTER FOURTEEN: RECENT PATENTS RELATED TO
THERMOFORMED PLASTICS 211
MOLDING OF POLYPROPYLENE WITH ENHANCED REHEAT
CHARACTERISTICS 211
THERMOFORMED SPORTS BOARD 211
THERMOFORMING PROCESS FOR PRODUCING CLASS “A”
FINISH, HIGH GLOSS AUTOMOTIVE EXTERIOR PARTS 211
FOAMED SHEET OF POLYLACTIC ACID RESIN AND METHOD OF
FOAM MOLDING 212
TWIN SHEET THERMOFORMING OF PLASTIC FUEL TANKS 212
THERMOFORMABLE POLYCARBONATE/POLYESTER
COMPOSITIONS AND USES 212
CHILLED AIR PRESSURE BOX FOR THERMOFORMING A
PLASTIC SHEET AND A METHOD OF THERMOFORMING THE
SAME 212
POLYCARBONATE PANEL ASSEMBLY FOR A VEHICLE 213
PROCESS FOR PRODUCING THERMOFORMED ARTICLES 213
METHOD OF THERMOFORMIN 213
POLYPROPYLENE POLYMER COMPOSITIONS AND PROCESS
FOR MAKING SAME 214
CHAPTER FIFTEEN: COMPANY PROFILES 215
ANCHOR PACKAGING 215
ASSOCIATED PACKAGING TECHNOLOGIES 215
BERRY PLASTICS CORPORATION 216
BRENTWOOD INDUSTRIES 217
CLEAR LAM PACKAGING 217
D & W FINE PACKAGES 218
DART CONTAINER CORPORATION 218
FABRI-KAL 219
GENPAK LLC 220
HUHTAMAKI AMERICAS 221
MULLINEX PACKAGING 222
PACTIV, INC 222
PAR-PAK LTD 223
PENDA CORPORATION 224
PENINSULA PACKAGING COMPANY LLC 224
PLACON, INC 225
PRENT CORPORATION 226
PRINT-PAK INC 226
REXAM CONTAINERS 227
SEALED AIR CORPORATION 227
SOLO CUP COMPANY 228
SONOCO CONSUMER PRODUCTS 229
SPARTECH CORPORATION 229
SPENCER INDUSTRIES 230
TEGRANT CORPORATION 231
TEKNI-PLEX 231
WILBERT PLASTIC SERVICES INC 232
WINPAK PORTION PACKAGING 232
APPENDIX: 233
ACRONYMS 233
ACRONYMS (CONTINUED) 234
ACRONYMS (CONTINUED) 235