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Transitioning from Rigid Clamshell to Lidding Film and Tray Packaging: Key Considerations

Jan. 14, 2025
Tomato in lidding film packaging

Transitioning from Rigid Clamshell to Lidding Film and Tray Packaging 

The shift from rigid clamshell packaging to lidding film and tray packaging offers benefits like cost savings, reduced material usage, and improved sustainability. However, the transition requires careful planning in material selection, design, and production processes. This article outlines key considerations to ensure a successful move to flexible packaging.

Material Selection and Compatibility

The first step in transitioning to lidding film and tray packaging is selecting appropriate materials. Rigid clamshells are typically made from plastics like PET or PVC, while lidding films are often made from flexible materials like PET, PP, or PE. The selected lidding film must be compatible with the tray material, and suitable for heat sealing or other sealing methods. The material must also provide adequate barriers for moisture, oxygen, and light to preserve product freshness. With growing demand for eco-friendly solutions, businesses should also consider compostable or recyclable films.

Design and Structural Adjustments

Lidding film and trays require different design considerations than rigid clamshells. The primary challenge is ensuring the product remains secure during transportation and storage. Unlike clamshells, which use complex geometries to hold products in place, tray and lidding packaging rely on sealing mechanisms. Companies must choose the right sealing method, such as heat sealing and adjust their packaging machinery accordingly. Changes may also be needed to ensure product visibility and branding, as lidding films don’t offer the same rigid transparency as clamshells. Transparent films or printed designs can help achieve similar visibility.

Production and Manufacturing Adjustments

Switching to lidding film and tray packaging requires adjustments in manufacturing processes. Lidding films and trays are typically produced using form-fill-seal machines, which require different equipment than the injection molding or thermoforming used for rigid clamshells. Production speeds and throughput may be impacted by the change in materials and machinery. Manufacturers may need to invest in new equipment or upgrade existing lines to accommodate flexible materials. Additionally, companies will need to coordinate with new suppliers for both film and tray materials, and adjust inventory and storage systems to accommodate these changes.

Sustainability Considerations

One of the main reasons companies shift to lidding film and tray packaging is to reduce material usage and environmental impact. Flexible packaging typically uses less plastic than rigid options, contributing to lower carbon footprints. However, companies should choose materials that are recyclable or compostable, as flexible films may be harder to recycle than rigid plastics. Clear disposal instructions and recycling labels on the packaging can help guide consumers to dispose of the packaging properly. 

 

If you require more help deciding or need additional resources on lidding film, get in touch with our sales team.