Blog
Vacuum Formed vs Pressure Formed Packaging: What’s the Difference?
When you’re choosing packaging for your product, the way it’s made can dramatically impact how it looks, feels, and performs. Two common manufacturing methods — vacuum forming and pressure forming — both fall under the thermoforming umbrella, yet produce very different results.
So how do you know which one is right for your business?
Let’s compare vacuum formed and pressure formed packaging, from finish quality to cost-effectiveness, and help you decide which method suits your product’s needs best.
What Is Vacuum Formed Packaging?
Vacuum forming is one of the simplest and most widely used thermoforming methods. Here’s how it works:
- A plastic sheet is heated until soft
- It’s then draped over a mould
- A vacuum pulls the sheet tightly against the mould to form its shape
This process is ideal for producing clear trays, blisters, inserts, and lightweight packaging components. It’s fast, affordable, and suitable for medium to high volumes.
Best for: Simple shapes, lower tooling costs, clear product displays
Discover our vacuum formed packaging solutions
What Is Pressure Formed Packaging?
Pressure forming is similar to vacuum forming — but adds compressed air to create a tighter, more detailed fit.
Here’s the process:
- The plastic sheet is heated
- It’s placed over a mould
- Vacuum pulls the sheet in, then compressed air applies extra pressure for finer detail
The result? Sharper edges, more texture, and a finish that can closely resemble injection moulding — but with lower costs.
Best for: Premium packaging, detailed textures, high-end product presentation
See our pressure formed packaging options
Fast Comparison
Vacuum forming uses suction to shape plastic around a mould — great for simple, clear trays.
Pressure forming adds compressed air to produce sharper detail and a premium look.
Choose vacuum forming for speed and affordability; opt for pressure forming when you need finer texture and upscale appeal.
Key Differences at a Glance
| Feature | Vacuum Forming | Pressure Forming |
| Detail/Texture | Basic | High definition |
| Tooling Cost | Lower | Slightly higher |
| Finish Quality | Glossy, clear | Matte or textured options |
| Speed | Fast | Moderate |
| Applications | Food trays, inserts, blisters | Premium retail, electronics, cosmetics |
The truth is, unless you compare the two side-by-side, it’s hard to see just how much of a difference pressure forming can make in visual appeal.
Which Industries Use These Methods?
Both methods are used across multiple sectors, but certain industries benefit more from one over the other:
- Vacuum Forming:
- Supermarkets & Food Brands – clear display trays for bakery, deli, confectionery
- Hardware & Electronics – protective plastic inserts
- Retail Displays – blister packs and clamshell packaging
- Pressure Forming:
- Cosmetics & Skincare – elegant trays and luxury retail packaging
- Premium Tech Products – high-end feel with precision finishes
- Medical Devices – sterile, structured packaging for safety and branding
Choosing the Right Option with Clear-Pak
At Clear-Pak, we offer both vacuum formed and pressure formed packaging — designed and manufactured right here in Australia.
Not sure which is best for your project?
We’ll guide you through:
- Product assessment to determine the right method
- Custom mould design for precise, brand-aligned results
- Fast, local production with recyclable materials like PET and RPET
Our team can help you balance budget, volume, and visual impact to find the perfect solution.
Let’s Talk Packaging That Fits — Perfectly
What would change if your product’s packaging didn’t just protect it — but actually enhanced its value?
Whether you need thousands of clamshells or a high-end tray for a new product launch, Clear-Pak can help.
Request a quote or speak with a packaging expert