Designed for you - without compromise

Everything Thermoform produces is entirely bespoke, designed specifically to meet our customers' needs, without compromise. It's something we have specialised in for over 40 years.

Because the whole process is on one site, managed and operated by one team, we are able to keep total control of the design and manufacture, producing bespoke solutions at a comparable price to off-the-shelf products.

Every new project starts with a first brief where the detail of the 'must have' features, such as eye catching presentation and protection during distribution are agreed.

An increasingly common request is for Thermoform to generate design concepts for our customers. We have an in-house Creative Design studio dedicated to inspire an extra boost of creativity and a spark of ideas to our customers projects. We work the design process from cradle to grave, creating and proposing ideas for our customers as well as seeing them through to the finished product.

We also help businesses improve the efficiencies of their auto denesting and robotic pick and place lines. This is something that can only be achieved through a bespoke design.

Using the latest CAD CAM technology our experienced our design team quickly create detailed drawings and prototype moulds. Initial product samples can then be presented to customers to conduct their own packing and transit trials or test marketing and promotion studies. Should revisions be required the development cycle is repeated until the best solution is found and the final design is approved.

The focus then moves through to our CNC engineering workshop where the same digital files that created the test samples are used to build a water cooled metal production tool needed for the full manufacturing run – once again all in house.

Manufacturing quality at the right price

Production of the final product - perhaps a tray, punnet, clam or blister - is carried out on one of a bank of fully automatic vacuum and pressure forming machines that form, cut and stack in-line. These machines are flexible and robust and can form both male and female shapes across a broad range of thickness and different plastics. Not all vacuum forming machines can do this.

The majority of items we make are for direct food use as retail packaging. Successful completion of intensive regular audits means that we can assure customers of their compliance with the rigorous standards required to maintain the highest 'AA grade' BRC certification.

Developed by the British Retail Consortium and Institute of Packaging, the Global Standard for Packaging & Packaging Materials is designed to assess the ability of packaging manufacturers to comply with food safety requirements and demonstrate due diligence.

Certification to the BRC/IOP Standard is widely regarded as representing the highest level of production and management controls for companies involved in the manufacture of food packaging. To find downloadable links to our certificates, please visit the bottom of the homepage.

 

BRIEF

The first stage of the design process is the brief. Our in-house design team have a wealth of packaging design experience and we work closely with our clients to understand their business objectives, before sitting down as a team to work on creative concepts.

Brief
Creative
CREATIVE

This is the stage where the ideas start to come to life.

We are passionate about our in-house design and innovation, and are able to provide hand drawn visuals alongside technical drawings, generated using the latest Computer Aided Design (CAD) software.

Sampling

All of our packaging is made to measure, and for this stage of the process we will create a 3D prototype mould. The initial samples are handmade, allowing us to make modifications and giving you the assurance that we are hands on to create the perfect form, fit and function for the piece of packaging to do its job.

These samples are a very close likeness to production quality, enabling you to see and test how the final product will look and perform.

Sampling
Tooling
Tooling

Upon approval of the prototype sample, we then get started on creating the final production tool. By converting the CAD drawing used to create the sample there is a smooth transition from design to production, which also ensures accuracy and speed for this process.

Our in-house toolmaking department uses state of the art CNC machines and decades of engineering experience to manufacture the parts and assemble each tool on site.

Then, prior to passing through to production, the tool is fully cleaned using an ultrasonic bath to ensure the highest levels of hygiene are maintained.

PRODUCTION

The production process at Thermoform happens in our adjacent building where the manufacture of the packaging takes place. We are accredited with BRC 'AA' grade, assuring that our quality and cleanliness is to the highest standard.

We are able to cater for any quantity, from 1 to 1 million and beyond, and make regular investment in new equipment to help us to operate effectively and efficiency.

We understand that our customers operate within a very dynamic environment and our business has grown over the years to ensure that we are able to rapidly respond with our lead times.

Production
Warehouse
WAREHOUSE AND DISTRIBUTION

Once the packaging has been manufactured, it is boxed up and palletised for storage in our onsite warehouse to await shipping.

Delivery is made either using our own vehicle or other approved couriers, shipping around the UK and overseas.