200 mm Deep Forming Technology for Thermoforming Packaging

Thermoforming packaging is widely used in modern food production because it integrates film forming, product loading, vacuum or gas filling, sealing, and cutting into one continuous process. However, when a product is especially tall, large, heavy, or irregular, conventional forming depths may not provide enough packaging space or protection.

To solve these demanding packaging challenges, Utien Pack continues to develop its thermoforming technology. In a whole Musang King durian packaging project for a customer in Malaysia, Utien Pack achieved a total forming depth of 200 mm through combined top and bottom film forming. This is a representative breakthrough in the packaging machinery industry and demonstrates the technical potential of Utien Pack thermoforming packaging machines.

What Is Deep Thermoforming Technology?

A thermoforming packaging machine heats the bottom film and forms it inside a mould. The formed package is then filled with the product, processed through vacuum or modified atmosphere packaging, sealed with the top film, and cut into individual packs.

For standard food products, forming only needs to create a shallow cavity. Large or tall products require a much deeper space. As forming depth increases, controlling film thickness, package strength, and forming consistency becomes more difficult.

Deep forming is therefore not simply a matter of stretching the film further. It requires accurate control of film heating, forming temperature, air pressure, vacuum level, forming time, mould structure, and film properties. These factors must work together to prevent the film from becoming too thin, tearing, deforming, or losing strength.

The Technology Behind 200 mm Forming

The Utien Pack 200 mm solution uses both top and bottom film forming. By creating space from two directions, the package can accommodate products that are difficult to place inside a conventional thermoformed cavity.

Accurate and uniform heating is essential. If the film is heated unevenly, some areas may stretch excessively while others may not form completely. Utien Pack controls the heating process so the film can soften evenly before entering the forming stage.

The forming pressure, vacuum process, and forming time must also match the film and mould. Precise process control helps distribute the film more evenly across the bottom, sides, corners, and edges of the package. This improves forming consistency and helps maintain the required package strength.

Mould design is equally important. Utien Pack develops the mould according to product dimensions, shape, weight, and surface features. The forming structure must provide enough internal space while reducing unnecessary stress on the film.

Packaging Challenges In Durian Export

Freshness preservation is one of the greatest challenges in durian packaging. Most durians supplied to customers in China are transported by sea or air. During long distance transportation, repeated movement and changes in temperature and humidity may accelerate flesh deterioration, causing the durian to become sour, soft, and less appealing. This contributes to a persistently high product loss rate. As durian is a high value fruit, excessive losses can significantly reduce profits and may also lead to customer complaints and disputes after delivery.

Durian also has a strong aroma that can easily spread without reliable packaging, causing discomfort to people who dislike the smell. Once the shell cracks, the exposed flesh may attract insects and become contaminated by dust or microorganisms, creating serious food safety risks.

Therefore, an effective durian packaging solution must preserve freshness, protect the fruit during transportation, prevent contamination, and limit aroma leakage.

Whole Musang King Durian As A Practical Example

The Malaysian Musang King durian project demonstrates how Utien Pack deep forming technology can solve a real packaging challenge. A whole durian is large, heavy, irregular, and covered with sharp spikes. It also has a strong aroma that can easily escape from ordinary packaging.

Freezing is commonly used to preserve durian for export. However, freezing may affect its original texture and eating experience. The customer therefore wanted a packaging solution that could support freshness, protect the whole fruit, extend shelf life, and reduce aroma leakage.

Utien Pack developed a globally original solution that combines forming film with paperboard. The forming film creates the main sealed package, while the paperboard provides additional support for the heavy and irregular durian. It also helps reduce the risk of the sharp shell damaging the film.

With a combined upper and lower forming depth of 200 mm, the package provides enough space for a whole Musang King durian. It can better match the three dimensional shape of the fruit while maintaining package stability and protection.

Vacuum And Modified Atmosphere Packaging

The solution supports both vacuum packaging and modified atmosphere packaging. The appropriate method can be selected according to the condition of the durian, storage requirements, transportation period, and target shelf life.

Vacuum packaging removes air before sealing. This helps reduce oxygen inside the package, limit aroma leakage, and create a stable package for storage and transportation.

Modified atmosphere packaging replaces the air with a selected gas mixture. It helps control the internal environment and supports freshness without applying excessive pressure to the product.

Reliable sealing is especially important because of the durian’s weight, sharp surface, and strong smell. Utien Pack uses powerful and controllable sealing pressure to create a stable seal and reduce the risk of leakage during handling and distribution.

Expanding The Application Of Thermoforming Packaging

The 200 mm forming depth is more than a technical figure. It shows that thermoforming packaging can be developed for products that are tall, large, heavy, sharp, or difficult to handle. The same technical experience can support more customized applications in food processing and other packaging fields.

Utien Pack develops each thermoforming solution according to the product, film structure, forming depth, packaging method, output target, and transportation conditions. From product testing and mould design to forming, vacuum, gas filling, sealing, and cutting, every process can be adjusted to the actual project.

Through continuous development of deep forming technology, Utien Pack is expanding the possibilities of thermoforming packaging. The whole Musang King durian project demonstrates how advanced forming capability and customized engineering can turn a difficult product into a practical, protective, and commercially valuable package.