Engineered multi-layer co-extruded films delivering maximum deep-draw thermoforming depth, puncture resistance, and ultra-high oxygen barrier protection for global food and medical brands.
PA/EVOH/PE co-extrusion engineered for high-speed thermoforming lines with zero pinholing and extended shelf life.
All-PE and All-PP thermoformable bottom webs designed for full recyclability without compromising speed or barrier.
Our thermoformable base webs undergo rigorous mechanical stress, oxygen permeability, and seal-integrity testing. Globally certified across North American, European, and Asian packaging standards.
For global procurement managers, packaging engineers, and supply chain directors, selecting the correct thermoformable base webs is the single most critical factor in mitigating product spoilage, downtime on automated packaging machinery, and elevated freight costs.
A thermoformable base web—often referred to as thermoforming bottom film, flexible bottom web, or forming film—is a multi-layer flexible plastic film fed into continuous rollstock packaging machines (such as Multivac, Ulma, Variovac, or Webmatic). Inside the machine's forming station, heat and air pressure/vacuum form the base web into a rigid or semi-rigid pocket. Products such as fresh red meat, processed poultry, cheese blocks, seafood, ready meals, or sterile medical syringes are loaded into this formed pocket before a top lidding film seals the package under vacuum or Modified Atmosphere Packaging (MAP).
Achieving structural integrity across corners and deep draws requires sophisticated resin engineering. Our multi-layer co-extrusion technology blends Polyamide (PA) for puncture resistance and thermoforming memory, Ethylene Vinyl Alcohol (EVOH) for gas barriers, Polyethylene (PE) for hermetic seals, and Polypropylene (PP) for retort thermal stability.
Choose from our specialized co-extruded film portfolios tailored for deep drawing, barrier performance, puncture resilience, and eco-design compliance.
Engineered for oxygen-sensitive perishable products like fresh meat, bacon, processed cheese, and smoked fish. Features 7 to 11 co-extruded layers delivering OTR < 1.0 cm³/m²/24h and moisture barrier < 2.5 g/m²/24h.
Specifically designed for aggressive bone-in meat cuts (ribs, chops, poultry), hard cheeses, and sharp-edged industrial parts. Formulated with ionomer-modified sealant layers and high PA content to eliminate Leaker Rates.
Future-proof sustainable bottom film constructed with >90% Polyethylene structure. Fully compliant with EU PPWR circular economy directives, offering smooth thermoforming draw for light to medium depth pockets.
Formulated with Polypropylene matrices to withstand autoclave microwave and thermal sterilization (up to 121°C/250°F for 30–60 minutes). Ideal for ready meals, pet food, and shelf-stable wet food packages.
Cleanroom-manufactured thermoformable films tailored for medical packaging (syringes, IV catheters, surgical kits). Compatible with Ethylene Oxide (EtO) and Gamma ray sterilization processes.
High-stiffness bottom webs engineered specifically for skin packaging machinery. Provides a rigid foundation for 3D skin top films to conform tightly around fresh steaks, fish fillets, and gourmet portions.
| Base Web Grade | Material Structure | Thickness Range | OTR (cm³/m²/24h) | WVTR (g/m²/24h) | Max Draw Depth | Target Applications |
|---|---|---|---|---|---|---|
| GPI-TB-Standard | PA / PE Multi-layer | 70µm – 200µm | < 25.0 | < 3.5 | 80 mm | Sausages, bacon, non-sensitive meats |
| GPI-TB-BarrierPlus | PA / EVOH / PE | 90µm – 300µm | < 0.8 | < 1.8 | 120 mm | Fresh beef, cheese blocks, MAP meals |
| GPI-TB-PunctureGuard | PA / Ionomer / PE | 150µm – 350µm | < 15.0 | < 2.0 | 100 mm | Bone-in ribs, frozen shellfish, hardware |
| GPI-TB-EcoMonoPE | HDPE / MDO-PE / LLDPE | 100µm – 220µm | < 2.0 (EVOH option) | < 2.5 | 60 mm | Recyclable retail protein & cheese packaging |
| GPI-TB-RetortPP | PP / EVOH / PP | 120µm – 280µm | < 0.5 | < 1.0 | 90 mm | Autoclaved ready-meals, pet wet food |
| GPI-TB-MedicalClean | PA / PE Cleanroom Grade | 100µm – 250µm | N/A (Sterile air) | < 2.0 | 75 mm | Surgical trays, catheter packages |
How evolving sustainability regulations, down-gauging technology, and high-speed automation are reshaping thermoformable base web procurement worldwide.
Global regulatory frameworks—such as the European Union’s Packaging and Packaging Waste Regulation (PPWR) and US State-level Extended Producer Responsibility (EPR) laws—are placing heavy penalties on unrecyclable multi-material structures like PVC/PE or unseparated PET/PE base webs.
Procurement teams are aggressively migrating to All-Polyethylene (Mono-PE) and All-Polypropylene (Mono-PP) thermoformable base webs. Our latest R&D breakthroughs allow MDO-PE (Machine Direction Oriented PE) to achieve high heat resistance and stretch memory, matching legacy PA/PE performance on thermoformers without compromising circular recycling metrics.
With volatile resin pricing and international carbon tax policies, food packaging brands are demanding thinner base webs that maintain structural rigidity. Legacy thermoforming bottom films required 200µm to achieve a 70mm draw depth without corner thinning.
By utilizing 11-layer nano-layer co-extrusion blown film technology, Graphic Packaging engineers 140µm base webs that deliver identical puncture resistance and thickness retention at pocket corners. Down-gauging reduces total polymer weight by up to 30%, resulting in lower material cost per pack and reduced transport emissions.
Modern automated packing operations operate at speeds exceeding 20 cycles per minute (CPM). Packaging downtime caused by web curling, chain sticker issues, or uneven film expansion during heating directly slashes operational profitability.
Procurement teams are prioritizing thermoformable base webs with precisely engineered Coefficient of Friction (COF 0.22–0.28) and controlled thermal shrinkage profiles. Our base webs feature balanced exterior anti-tack layers that prevent film distortion during thermoforming heat contact, guaranteeing maximum uptime on Multivac, Ulma, and Variovac equipment.
Deep dive into the material science behind our thermoformable base webs, engineered to withstand extreme deep drawing, vacuum draw down, and aggressive food environments.
Our state-of-the-art blown film extrusion lines utilize up to 11 distinct extruder barrels. By sandwiching EVOH oxygen barrier layers between dual PA structural layers and PE sealant resins, we eliminate moisture-induced EVOH degradation while maintaining zero-curl film layflat balance.
Every roll of thermoformable base web is produced with online continuous laser micrometer monitoring, keeping thickness variation under ±2.5%. Advanced polymer rheology guarantees uniform neck-down and stretch ratio during thermoforming mold elongation.
Leaker rates are a major source of shrink loss for meat processors. Our base webs integrate advanced metallocene LLDPE and Surlyn ionomer sealant layers that fuse hermetically through blood, fat, brine, and spice contaminants during thermal sealing.
Tired of film breakage, corner pinholes, or high leaker rates on your thermoformers? Our technical engineers will audit your machine parameters and supply custom-slit test rolls for qualification.
As a global enterprise listed on the New York Stock Exchange (NYSE: GPK), Graphic Packaging International provides unmatched financial stability, supply chain security, and multi-plant manufacturing redundancy across North America, Europe, and Asia-Pacific.
We manage resin sourcing, co-extrusion film blowing, slitting, print enhancement, and packaging machinery integration under one corporate umbrella. This single-source accountability ensures your packaging films and thermoforming machinery work in perfect harmony.
A seamless, risk-free technical onboarding program designed for procurement, QA, and packaging operation leaders.
We evaluate product draw depth, shelf-life target, barrier requirements, and machine specs.
Selection of resin structure (PA/PE, EVOH, Mono-PE), thickness gauge, and roll slit width.
Tensile stress, puncture resistance, OTR/WVTR, and thermal seal curve verification.
On-site machine trial of slit rollstock to optimize forming temperatures and speed.
Commercial rollstock supply backed by VMI stock programs and global field technical support.
Expert answers to the top technical and procurement questions asked by global packaging buyers and AI queries.
Partner with a world leader in high-barrier co-extrusion and sustainable flexible packaging films. Reduce leaker rates, eliminate pinholes, and achieve complete circular economy compliance.
Graphic Packaging International is an equal opportunity employer committed to innovation, sustainability, and quality. All product specifications, barrier test metrics, and material recommendations are backed by our global technical service and certified laboratory testing protocols.