What is the difference between thermoforming cups and thermoforming trays?

Thermoforming cups and thermoforming trays follow the same fundamental process, but they differ significantly in mold geometry, material selection, tooling design, and the production speeds achievable. Cups are deep-drawn, cylindrical or tapered containers, while trays are shallow, wide, and often rectangular. Understanding these differences helps manufacturers choose the right equipment, materials, and process parameters for their specific packaging needs. The sections below address the most common questions about cup and tray production side by side.

How does the thermoforming process differ for cups versus trays?

The core thermoforming process is the same for both: a plastic sheet is heated until pliable, then formed into shape using a mold, trimmed, and stacked. The key difference lies in draw depth and forming direction. Cups require deep drawing, meaning the material is stretched significantly downward into a narrow cavity. Trays are formed over a shallower, wider mold with less vertical stretch.

Deep drawing for cups demands precise control of material distribution. If the sheet is not heated evenly or the draw ratio is too aggressive, the sidewalls of the cup can thin unevenly, leading to weak spots. Tray forming is generally less demanding in terms of draw depth, but the wider surface area introduces its own challenges, particularly around corner definition and consistent wall thickness across a large footprint. Both formats benefit from optimized plug-assist systems that pre-stretch the material before the vacuum or pressure forming step begins.

What materials are used for thermoforming cups and trays?

Both cups and trays are commonly produced from polystyrene (PS), polypropylene (PP), and polyethylene terephthalate (PET). The choice of material depends on the end application, required barrier properties, and whether the packaging needs to be transparent, heat-resistant, or suitable for recycling. PP is the dominant material for food cups like yogurt tubs, while PET is widely used for trays requiring clarity and rigidity.

For cups, PP is favored because it tolerates hot-fill applications and offers good chemical resistance for dairy products. PET cups are popular where transparency is a selling point. For trays, PET and CPET (crystallized PET) are common choices, especially for ready-meal trays that need to withstand oven temperatures. Recycled PET (rPET) is increasingly used in both formats as manufacturers respond to sustainability requirements. Biodegradable materials such as PLA are also entering the market for both cups and trays, particularly in the food service sector.

Which food packaging applications use cups versus trays?

Cups are primarily used for portion-controlled, liquid or semi-liquid food products. Trays serve a broader range of solid and multi-component food formats. The distinction largely follows the shape of the product being packaged: if it pours or scoops, it typically goes into a cup; if it sits or layers, it typically goes into a tray.

Typical cup applications

Yogurt and dairy dessert tubs
Margarine and spreadable fat containers
Coffee capsules
Portion cups for condiments and sauces
Beverage cups and lids

Typical tray applications

Ready-meal and convenience food trays
Fresh produce and berry containers
Meat and fish packaging
Bakery and confectionery trays
Snack and deli portion trays

Food packaging remains the largest single segment for thermoformed plastic packaging, and both cups and trays play central roles within it. Manufacturers operating in dairy, coffee, or condiment production lean heavily toward cup formats, while those in ready meals, fresh produce, and protein packaging rely on trays.

How do tooling and mold design differ between cup and tray production?

Cup molds are designed around a high draw ratio, with tall, narrow cavities that require careful plug geometry to distribute material evenly down the sidewalls. Tray molds are wider and shallower, with the design challenge focused on achieving sharp corner radii and consistent depth across a large forming area. Both require precise temperature control within the mold itself to ensure dimensional stability.

Cup tooling typically uses a higher cavity count per tool because the individual cup footprint is small. A single forming station can produce dozens of cups per cycle. Tray tooling uses fewer cavities per tool because each tray occupies more of the forming area. The trimming tool design also differs: cup stacks require in-mold or downstream cutting that follows a circular or tapered profile, while tray trimming follows a rectangular or irregular perimeter. Tool wear patterns differ accordingly, with cup tools experiencing more stress at the base of the cavity due to the deep drawing motion.

What production speeds can thermoforming machines achieve for cups and trays?

Production speed in thermoforming is measured in cycles per minute and depends on material type, part geometry, and machine design. Cup production generally achieves higher cycle rates than tray production because the smaller forming area and simpler stacking geometry allow faster machine movements. High-end thermoforming machines can achieve significantly higher output than standard systems through optimized drive technology and motion sequencing.

The cycle rate for cup production is influenced primarily by the cooling time required after forming, the number of cavities in the tool, and the speed of the stacking and counting system downstream. Tray production cycles are typically slower per cycle but can still achieve high output per hour when the tooling is designed for multiple cavities. The drive system of the machine plays a decisive role: machines using separate servo drives for lifting and forming motions can execute more precise and faster movement sequences, reducing cycle time without increasing mechanical wear.

Stacking and downstream handling also affect effective output. Cup stacking is well-suited to automated inline systems, while tray stacking requires more space and handling flexibility depending on the tray geometry and whether a lidding or sealing step follows.

Should you use the same thermoforming machine for both cups and trays?

Yes, it is possible to produce both cups and trays on the same thermoforming machine, provided the machine is designed for flexible tooling changes and covers the required forming area and draw depth for both formats. Multi-format capability is a genuine advantage for manufacturers who need to switch between product lines without investing in separate dedicated machines.

The key considerations when evaluating a machine for dual-format production are forming area, maximum draw depth, and how quickly the tooling can be changed between formats. A machine with a wide forming station and a robust clamping system can accommodate both shallow tray tools and deep cup tools. However, a machine optimized purely for high-speed cup production may not offer the forming area or flexibility needed for larger tray formats. Manufacturers with diverse product portfolios benefit most from machines built around flexibility rather than single-format speed optimization. Exploring the available thermoforming machine product lines can help clarify which configuration suits a mixed production environment.

How GABLER Thermoform supports cup and tray production

We at GABLER Thermoform develop and manufacture high-end thermoforming machines designed to handle the full range of plastic packaging formats, including both thermoforming cups and thermoforming trays. Our machines are built in Lübeck, Germany, and serve manufacturers from SMEs to global players across the food packaging industry. Here is what we offer:

Flexible machine lines: Our product range covers compact stand-alone machines through to large-scale complete lines with extrusion and process linking, giving you the right solution for single-format or multi-format production.
Optimized drive technology: Separate servo drives for lifting and swiveling motion, combined with innovative crankshaft technology, deliver faster cycle rates, minimal tool wear, and up to 20 per cent higher output than comparable systems.
Material versatility: Our machines process standard materials including PP, PS, and PET, as well as recycled PET and biodegradable PLA foil, supporting your sustainability goals.
Industry 4.0 readiness: State-of-the-art sensor technology and remote access keep your production connected and your downtime low.
Full-service support: From installation and tooling advice to spare parts supply and customer service, we cover every detail so you can focus on production.

If you are evaluating thermoforming equipment for cup production, tray production, or both, we are ready to help you find the right solution. Contact us at GABLER Thermoform to discuss your production requirements with our team.