PMC scales paper thermoforming to 250 trays per minute at Pack Expo

Moving Fiber Packaging to High-Volume Reality

Pack Expo International 2026 opens its doors today at McCormick Place in Chicago, and the shift toward fiber-based packaging is moving definitively from prototype to high-volume reality. Paper Machinery Corporation (PMC) is utilizing Booth S-1630 to demonstrate the TP3820 Paper Thermoforming Press, a system engineered to push paperboard tray production to genuine industrial speeds.

The core metric defining the TP3820 is its output capacity: up to 250 trays per minute. This is achieved through a five-lane configuration running at 50 strokes per minute. Unlike slower legacy systems that struggled with material versatility, this press accommodates both solid board and corrugated materials. By utilizing pre-cut blanks, the machine allows converters to leverage their existing printing and die-cutting assets rather than requiring entirely new upstream workflows, a crucial factor for facilities looking to manage capital expenditure while expanding their fiber capabilities.

Operational Flexibility and Tooling Efficiency

Speed without flexibility is a liability in today's converting environment, where run lengths are shrinking and SKU proliferation continues. PMC has engineered the TP3820 with adjustable dwell, stroke height (up to 14 inches), and forming force. This level of control is essential when switching between different board grades and tray depths (up to 4 inches).

Tooling changeovers, traditionally a significant bottleneck in thermoforming operations, have been addressed directly. The TP3820 allows for tooling changes in under 30 minutes, supported by a dedicated die cart system weighing approximately 1,000 lbs that streamlines storage and changeover logistics. The machine also features an intuitive HMI touchscreen and a draw ring part eject method, ensuring consistent performance across multiple tray sizes simultaneously.

Adam Wescott, Vice President of Sales & Marketing at PMC, noted the strategic timing of the launch. "PACK EXPO gives us an opportunity to show customers what paper thermoforming looks like in an actual production environment," Wescott stated. "The TP3820 builds on PMC's experience in paper forming while giving customers greater flexibility in the types of packages they can produce."

Meeting the Demand for Structural Integrity

As brands push to replace single-use plastics with recyclable fiber alternatives, the industry bottleneck has often been the forming speed and structural integrity of paper trays. The TP3820 addresses this gap directly. By handling corrugated materials alongside solid board, it opens avenues for heavier-duty applications, such as fresh produce or protein packaging, where structural rigidity and moisture resistance are non-negotiable.

The ability to form 250 paper trays per minute proves that fiber packaging can finally match the operational cadence of legacy plastic thermoforming lines, removing a major barrier to sustainable packaging adoption. Will converters be able to optimize their upstream die-cutting operations to keep these high-speed presses running at maximum capacity? Follow The Paper for daily news, market signals and key updates from the global paper, corrugated and packaging industry. — Sigue toda la actualidad del sector en www.thepaper.ai