One thing that stood out at the 2025 International Production & Processing Expo (IPPE) was the high level of innovation in thermoforming technology for meat and poultry processors.

This innovative packaging solution not only enhances product preservation and shelf-life but also minimizes environmental impact, addressing rising consumer demand for sustainable practices. That’s led manufacturers to increasingly adopt cutting-edge thermoforming techniques, which streamline production processes and improve food safety standards, ensuring that consumers receive high-quality products.

“Recent advancements in thermoforming include the increased use of vacuum skin packaging (VSP), particularly for portion-cut steaks in saddle packs and other meat products,” said Jay Siers, case ready specialist at Taunton, Mass.-based Harpak-Ulma Packaging LLC. “This method extends shelf life while maintaining product quality. Additionally, saddle packs for whole cut-up chicken, commonly used by retailers like Costco and Walmart, allow for improved packaging integrity and preservation.”

Andrew Birdwell, national sales director for Battleboro, NC-based Ossid, a ProMach brand, said one of the biggest advantages in recent thermoforming advancements is the ability to run multiple packaging formats — including lidding, Modified Atmosphere Packaging (MAP), vacuum and VSP.

“This flexibility allows processors to select the best solution for product integrity, extended shelf life and enhanced presentation,” he said. “Additionally, improvements in barrier films from material suppliers have significantly increased shelf life, offering better protection against spoilage and waste.”

Chris Coad, technical product manager for thermoforming at Kansas City, Mo.-based Multivac Inc., noted the company keeps hygienic design top of mind when designing equipment.

“We take this very seriously regarding the cleanability of our machines,” he said. “We also ensure our machines are safe for our customers to operate. We don’t sacrifice one for the other. All of our thermoforming equipment is designed with an ‘open frame’ design. No hollow tubes or flat spots for harborage of debris, which can lead to bacterial growth.”

Harpak-Ulma's latest thermoforming technology facilities rigid or flexible film with MAP and vacuum options. (Source: Harpak-Ulma)

New at IPPE

There was a lot to see regarding this tech at this year’s IPPE, held at the Georgia World Congress Center in Atlanta in January.

For instance, Harpak-Ulma showcased the TFS600 at the show, a thermoformer with a strong focus on sanitary design.

“This machine meets 3A sanitary design standards, a feature not commonly promoted in the meat industry but highly appreciated by processors looking for higher hygiene standards,” said Ken Forziati, the company’s product manager for thermoforming. “Additionally, our vision system integration through ULMA Vision was a key highlight, offering improved quality control capabilities. Our innovations cater to meat and poultry processors by enhancing food safety, improving efficiency, and aligning with modern automation needs.”

Multivac showcased its technology of MultiFresh packaging, which provides a skin-tight package showcasing the product to give it an almost painted-on product appearance.

“It is a very high-end package,” Coad said. “We also showcased automation. As labor is more difficult to find, we have been manufacturing line solutions for our customers.”

Amcor Flexibles North America introduced its Revolution sortable barrier APET trays, a breakthrough in sustainable packaging.

“This innovative technology enables the APET layer to separate from the PE layer in a water tank at plastics recycling facilities, allowing the PET to be curbside recycled,” said Melanie Bandari, senior marketing manager for Amcor.

She noted FreshCase active vacuum packaging technology from Amcor solves the vacuum packaging challenge by delivering meat that blooms fresh and maintains its bright color throughout an extended shelf life.

“Meat stays fresh after purchasing seven times longer than PVC-wrapped cuts,” she said. “Meats age naturally and tenderize right in the package. FreshCase uses less refrigerator space than MAP packages and eliminates messy leaks in shopping bags, refrigerators, counters and freezers.”

What’s more, Amcor’s new value-added Poultry ICE film technology is helping poultry packaging by actively interacting with the product to reduce bacteria, minimize odors and extend shelf life by up to 40%.

Ossid’s focus with thermoforming technology is centered on enhancing ease of use for operators, streamlining the changeover process to minimize downtime and improving overall machine performance and efficiency.

“Additionally, we offer tailored preventative maintenance programs to ensure our customers’ systems operate at peak performance, maximizing uptime and extending the longevity of their equipment,” Birdwell said.

Amcor's thermoforming solutions offer flexibility for multiple applications. (Source: Amcor)

Sustainability measures

Sustainability remains a driving force in packaging innovation, with continued efforts to develop more eco-friendly materials and manufacturing processes.

“Throughput and line speed remain critical factors for meat and poultry processors, making tray overwrap a smart choice for its proven efficiency, cost-effectiveness and high-speed output.

“However, thermoform fill seal technology continues to evolve, offering processors another reliable option that delivers high-quality packaging at increasingly competitive speeds,” Birdwell said.

Harpak-Ulma has developed Better-Seal and EcoForm materials that provide better sealing while being more sustainable.

“These materials reduce waste while maintaining product integrity,” Forziati said. “Additionally, our advanced sealing technology lowers the energy required for packaging by optimizing the sealing process, reducing overall resource consumption.”

Thermoforming innovations

Automation is playing a major role in increasing efficiency, particularly through pick-and-place technology and auto-loading systems. For instance, Siers noted Harpak-Ulma’s collaboration with Cabinplant enhances automation capabilities, including multihead weighing, helping processors optimize labor use and increase throughput.

“These advancements streamline production, reduce labor dependency and improve overall efficiency in thermoforming lines,” he said.

Future trends in thermoforming will most likely focus heavily on smart connected machines and augmented reality support for maintenance and troubleshooting, the experts predict.

“Our AR overlay technology, developed through PTC, enables operators to perform preventative maintenance and repairs more efficiently, minimizing downtime,” Forziati said. “Additionally, our HUP Academy online training tools will play a significant role in educating operators on best practices, further optimizing OEE. The continued push toward automation, data-driven decision-making and sustainability will drive thermoforming innovation in the coming years.”

As advancements in thermoform fill seal improve efficiency and performance, it is becoming an increasingly viable solution to meet the diverse needs of the industry.