Thermoform Packaging Revolution: What Will Transform High-Throughput Labs by 2025–2030?

Executive Summary: The State of Thermoform Packaging in High-Throughput Labs (2025)
Market Size and Growth Outlook Through 2030
Key Drivers: Automation, Sustainability, and Regulatory Shifts
Emerging Thermoforming Materials and Smart Packaging Solutions
Top Manufacturers and Innovators (e.g., sonoco.com, tekni-plex.com)
Adoption Challenges: Integration, Cost, and Quality Assurance
Applications Spotlight: Genomics, Diagnostics, and Pharma Workflows
Competitive Landscape and Strategic Partnerships
Sustainability Trends: Recyclability, Bio-Based Advances, and Compliance
Future Outlook: Technology Roadmap and Disruptive Innovations
Sources & References

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Executive Summary: The State of Thermoform Packaging in High-Throughput Labs (2025)

Thermoform packaging has rapidly become an essential component in high-throughput laboratory environments, driven by demands for efficiency, sterility, and automation compatibility. As of 2025, adoption of thermoformed lab consumables and packaging—such as PCR plate trays, reagent reservoirs, and custom sample containers—continues to accelerate, responding to the needs of pharmaceutical, clinical diagnostics, genomics, and biobanking laboratories.

Thermoforming allows for the production of lightweight, durable, and customizable packaging at high volumes, aligning with the throughput and automation requirements of modern labs. Major suppliers like Thermo Fisher Scientific and Corning Incorporated have expanded their portfolios of thermoformed microplates, tube racks, and transport trays, while also investing in automation-ready, stackable formats to increase efficiency in robotic workflows. Notably, Eppendorf and Sarstedt AG & Co. offer pre-sterilized and sealed thermoform packaging for consumables, addressing contamination concerns critical to high-throughput screening and sample integrity.

Sustainability and material innovation are increasingly influencing product development. Suppliers are introducing recyclable and bio-based plastics to align with laboratory sustainability initiatives. For example, Greiner Bio-One International has publicly committed to developing thermoformed packaging solutions utilizing recycled PET and renewable materials, forecasting the launch of several new lines in late 2025 and early 2026.

Automation compatibility remains a key driver. Thermoform packaging is being optimized for seamless integration with automated liquid handlers and sample tracking systems. Industry collaborations, such as those between Thermo Fisher Scientific and major automation companies, aim to standardize packaging dimensions and features to reduce manual intervention and streamline laboratory logistics.

Looking forward, the thermoform packaging sector is expected to see continued growth in laboratory adoption, fueled by increased demand for high-throughput testing (notably in molecular diagnostics and biobanking), regulatory emphasis on sample traceability, and the expansion of personalized medicine. The next few years will likely bring further innovations in sustainable materials, smart packaging (e.g., embedded RFID), and enhanced automation interfaces. Leading suppliers are well-positioned to deliver solutions that support both operational efficiency and evolving compliance standards in high-throughput laboratory settings, cementing thermoform packaging as a backbone of modern lab workflows.

Market Size and Growth Outlook Through 2030

The market for thermoform packaging tailored to high-throughput laboratories is entering a growth phase driven by expanded clinical diagnostics, pharmaceutical research, and biobanking activities worldwide. As of 2025, increased automation and sample processing volumes in laboratories are intensifying the need for precision-engineered, contamination-resistant packaging solutions. Thermoformed packaging—including microplate lids, reagent trays, and custom sample containers—has become foundational for protecting sample integrity and ensuring compatibility with automated liquid handling and robotic systems.

Major manufacturers such as Thermo Fisher Scientific and Corning Incorporated have reported robust demand for customizable, automation-compatible packaging formats, citing growth in molecular diagnostics and next-generation sequencing (NGS) workflows as key drivers. For instance, Thermo Fisher Scientific continues to expand its range of thermoformed consumables to support increasing throughput and the shift toward personalized medicine, while Corning Incorporated has ramped up investments in advanced material science to enhance the performance of its laboratory plasticwares.

The rise of centralized laboratory networks and biobanks, particularly across North America, Europe, and Asia-Pacific, is also boosting the requirement for secure, traceable packaging with advanced barcoding and sealing features. Companies like SARSTEDT AG & Co. KG are responding with innovative product lines that address both sample security and regulatory compliance for high-throughput settings.

Looking ahead to 2030, industry forecasts by leading sector participants point to a compound annual growth rate (CAGR) in the mid- to high single digits, with the global market value for laboratory-targeted thermoform packaging expected to exceed several billion USD by the decade’s end. Environmental considerations are shaping product development, as manufacturers such as Gerresheimer AG are introducing recyclable and reduced-plastic content packaging solutions to meet sustainability mandates imposed by both public and private sector clients.

In summary, the outlook for thermoform packaging in high-throughput laboratories through 2030 is characterized by technological innovation, regulatory evolution, and the ongoing transformation of laboratory workflows. Industry leaders anticipate sustained investment in packaging formats that support automation, biosafety, and sustainability, positioning the sector for steady expansion over the next several years.

Key Drivers: Automation, Sustainability, and Regulatory Shifts

The landscape of thermoform packaging for high-throughput laboratories is being rapidly reshaped in 2025 by three interlinked forces: automation, sustainability, and evolving regulatory frameworks. These drivers collectively dictate the design, material selection, and adoption rates of thermoformed packaging solutions in sectors such as clinical diagnostics, pharmaceuticals, and life sciences.

Automation: The surge in high-throughput workflows—accelerated by advances in laboratory robotics and digital integration—demands packaging that is precisely engineered for compatibility with automated systems. Thermoform packaging now features tighter tolerances, enhanced stackability, and RFID or 2D barcode integration for seamless robotic handling and traceability. Companies such as Thermo Fisher Scientific and Eppendorf SE have expanded their portfolios of automation-ready thermoform trays and plates, responding to the need for error-proof sample logistics and high-speed processing in genomics, drug discovery, and clinical testing environments.
Sustainability: The push for greener laboratories is translating directly into packaging innovation. In 2025, there is a marked shift toward mono-material thermoform designs that improve recyclability and reduce landfill waste. SABIC and BASF are supplying advanced polymers—such as bio-based PET and chemically recycled plastics—enabling suppliers to offer packaging that meets both performance and sustainability criteria. Additionally, manufacturers like Bemis Company, Inc. are piloting closed-loop recycling programs tailored for laboratory packaging waste streams, helping clients meet increasingly stringent environmental targets.
Regulatory Shifts: Regulatory bodies are enacting new directives around material safety, traceability, and waste minimization. For instance, the European Union’s tightening rules on single-use plastics and the US FDA’s guidance on primary packaging for diagnostic reagents are prompting manufacturers to rethink resin choices and labeling strategies. Leading packaging suppliers like Spartan Packaging are investing in compliance-ready production lines, incorporating features such as tamper-evidence, serialization, and material provenance tracking to ensure readiness for current and forthcoming regulatory landscapes.

Looking ahead, the convergence of these drivers will continue to propel innovation in thermoform packaging, with emphasis on automation compatibility, eco-conscious material selection, and robust regulatory compliance. The sector’s outlook for the next several years suggests ongoing collaboration between polymer producers, packaging converters, and laboratory automation specialists to deliver solutions that are efficient, sustainable, and future-proof.

Emerging Thermoforming Materials and Smart Packaging Solutions

Thermoform packaging has become increasingly vital for high-throughput laboratories, particularly in the context of sample handling, automation compatibility, and contamination control. As laboratories continue to expand their throughput capabilities—driven by growth in diagnostics, pharmaceutical research, and biobanking—the demand for advanced thermoforming materials and smart packaging solutions is accelerating into 2025 and beyond.

A key trend is the shift toward specialty polymers and engineered films that provide improved chemical resistance, clarity, and barrier properties. For example, Gerresheimer has advanced its use of cyclic olefin copolymers (COC) and cyclic olefin polymers (COP) in thermoformed labware, offering high purity and low leachables, which are critical for sensitive assays and automated workflows. Similarly, Thermo Fisher Scientific employs precision thermoforming for microplate manufacturing, ensuring consistent well geometry and robust sealing for high-throughput screening.

Smart packaging concepts are also gaining ground, integrating features such as RFID tags, QR codes, and embedded sensors. These enable real-time tracking, inventory management, and even environmental monitoring of samples. Sartorius has begun incorporating smart labeling and anti-counterfeiting tags into select consumables, streamlining sample traceability and compliance with data integrity standards.

In terms of sustainability, leading suppliers are responding to laboratory demand for greener solutions. SABIC, a major supplier of medical-grade polymers, is promoting circular polymer solutions and bio-based plastics for thermoforming applications. Their portfolio now includes ISCC PLUS-certified materials, supporting laboratories in their efforts to reduce their environmental footprint.

Looking to 2025 and the next several years, the outlook for thermoform packaging in high-throughput laboratories is defined by further integration with laboratory automation systems, enhanced material performance, and digital connectivity. Manufacturers are also expected to expand in-region production to ensure supply chain resilience and rapid response to local regulatory demands. As high-throughput labs seek ever-greater efficiency, precision, and compliance, thermoform packaging will continue to evolve as a key enabler of operational and scientific advancement.

Top Manufacturers and Innovators (e.g., sonoco.com, tekni-plex.com)

The landscape of thermoform packaging for high-throughput laboratories is shaped by a select group of global manufacturers and innovators who are responding to the rising demand for precision, contamination control, and automation compatibility in laboratory workflows. As 2025 unfolds, these companies are leveraging advanced materials and digital manufacturing to support the life sciences, diagnostics, and pharmaceutical sectors.

One of the leading players, Sonoco, continues to expand its portfolio of custom thermoformed trays and blister packaging, tailored for laboratory consumables such as microplates, reagent reservoirs, and pipette tip racks. Their focus on sustainability, with initiatives to incorporate recycled content and design for recyclability, aligns with broader environmental goals prominent in the laboratory industry.

Another major innovator, Tekni-Plex Healthcare, has invested in new thermoforming lines and cleanroom capabilities to meet the sterility and traceability demands of high-throughput laboratories. Their barrier films and custom tray solutions enable extended shelf life and product integrity for sensitive diagnostic and pharmaceutical components. Tekni-Plex’s expansion of its global footprint, especially in North America and Europe, is positioned to meet the surging demand for rapid diagnostics and automation-ready packaging.

In the European sector, S.R.Packaging has developed specialized thermoformed packaging for laboratory automation, emphasizing precise cavity design and antistatic properties. Their recent focus has been on providing packaging compatible with robotic handling, which is crucial for high-throughput screening and automated liquid handling systems.

Additional innovation is seen from Klosterfrau Packaging, which is advancing the integration of RFID and QR code tracking into thermoform packaging for traceability and workflow optimization. Their emphasis on quality assurance and in-line inspection systems is helping laboratories meet stringent regulatory requirements.

Looking ahead, these manufacturers are expected to prioritize digital integration—such as unique identification and smart packaging features—and invest in eco-friendly materials. The continued trend toward automation and the growth of high-throughput diagnostics will drive demand for precisely engineered thermoform packaging, with the top companies positioned to deliver innovation, scalability, and compliance in the coming years.

Adoption Challenges: Integration, Cost, and Quality Assurance

The adoption of thermoform packaging in high-throughput laboratory environments is advancing rapidly in 2025, yet several significant challenges remain related to integration, cost, and quality assurance. As laboratories continue to scale up automation and sample volume, the need for reliable, scalable, and compatible packaging solutions becomes paramount.

Integration Challenges: Laboratories utilizing robotic liquid handlers, automated storage, and high-speed sample processing platforms must ensure that thermoform packaging formats are compatible with existing automation. Issues such as precise dimensional tolerances, stackability, and machine readability (barcoding or RFID integration) are recurring concerns. Leading suppliers like Thermo Fisher Scientific and Eppendorf SE are addressing these integration hurdles by collaborating directly with automation equipment manufacturers to standardize tray and plate formats, but custom packaging requirements still pose logistical barriers for smaller labs and novel workflows.

Cost Pressures: Rising material prices in 2025, especially for medical-grade polymers such as PET and COC, are impacting the cost-effectiveness of thermoform packaging. Bulk procurement and long-term contracts offered by suppliers like ALPLA Group help to stabilize pricing for large-scale purchasers, but smaller laboratories and contract research organizations (CROs) report higher per-unit costs compared to traditional injection-molded or pre-formed consumables. Moreover, the transition to recyclable and biodegradable plastics, a response to sustainability demands, often involves higher initial capital investment and changes in supply chain logistics, as noted by Gerresheimer AG.

Quality Assurance: In regulated environments, packaging quality directly affects sample integrity and traceability. Maintaining consistency in wall thickness, seal integrity, and particulate control is essential for compliance with ISO 13485 and FDA cGMP standards. Major manufacturers, including Sonoco Products Company, are expanding in-line inspection capabilities and digital traceability (e.g., serialization and digital twins) to provide real-time quality data. However, rapid design changes and accelerated production timelines—driven by the demands of high-throughput diagnostics—sometimes lead to variability between production batches, posing risks for sample contamination or process disruption.

Outlook: Over the next few years, ongoing collaboration between packaging suppliers, automation vendors, and laboratory end-users is expected to yield greater standardization and interoperability. Advances in digital manufacturing and the adoption of Industry 4.0 principles are anticipated to enhance both integration and quality assurance, while continuous materials innovation could help mitigate cost pressures as sustainable options become more widely available and economically viable.

Applications Spotlight: Genomics, Diagnostics, and Pharma Workflows

Thermoform packaging is experiencing notable growth and innovation in high-throughput laboratory settings, particularly in genomics, diagnostics, and pharmaceutical workflows. As laboratories scale up operations to meet increasing demand for rapid, reliable, and cost-effective sample processing, the adoption of thermoformed solutions—such as multiwell plates, reagent reservoirs, and custom sample trays—has accelerated. This trend is underpinned by the need for automation compatibility, contamination control, and efficient logistics.

In 2025, leading manufacturers are optimizing thermoform packaging to align with the requirements of next-generation sequencing (NGS), automated liquid handling, and high-throughput screening. For instance, Thermo Fisher Scientific continues to refine its portfolio of consumables, including custom thermoformed plates and reservoirs that integrate seamlessly with robotic systems, reducing manual intervention and error rates. Similarly, Corning and Eppendorf are introducing precision-engineered thermoformed products designed for enhanced sample integrity and throughput in genomics and diagnostic applications.

Sustainability and regulatory compliance are also driving material innovations. Gerresheimer has expanded its range of recyclable and medical-grade thermoformed packaging, supporting the pharma sector’s shift toward more sustainable laboratory practices. This is increasingly important as both pharmaceutical companies and clinical laboratories aim to minimize their environmental footprint without compromising quality or regulatory standards.

Recent years have seen a surge in demand for diagnostic consumables—such as PCR plates, sample collection trays, and transport packaging—prompted by global health challenges and the expansion of decentralized testing. SARSTEDT and Sterilin (now part of Thermo Fisher Scientific) are among suppliers scaling up their thermoforming capabilities to support high-volume production and rapid distribution. Their advanced packaging solutions are tailored to ensure biosecurity, chain-of-custody, and automation readiness across diagnostic and pharmaceutical distribution networks.

Looking ahead, the outlook for thermoform packaging in high-throughput laboratories is robust. With ongoing advances in personalized medicine, molecular diagnostics, and drug discovery, demand for high-quality, automation-friendly, and sustainable packaging is expected to continue rising through the late 2020s. Manufacturers are investing in smarter design, digital integration (such as RFID and barcoding), and closed-loop recycling systems, positioning thermoform packaging as a linchpin in the evolving landscape of laboratory automation and sample stewardship.

Competitive Landscape and Strategic Partnerships

The competitive landscape for thermoform packaging in high-throughput laboratories is evolving rapidly in 2025, driven by the convergence of automation trends, sustainability imperatives, and increasing demand for precision in sample management. Key industry players are seeking to differentiate themselves through innovation in materials, design flexibility, and integrated solutions tailored for automated laboratory workflows.

Leading manufacturers such as Thermo Fisher Scientific and Corning Incorporated continue to expand their portfolios of thermoformed consumables, including deep-well plates, PCR trays, and custom sample organizers. These companies are investing in advanced polymer technologies to provide improved chemical resistance, reduced extractables, and enhanced compatibility with robotic handling systems. In 2025, Thermo Fisher Scientific has underscored its commitment to laboratory automation by launching new lines of automation-ready, recyclable thermoform racks and plate covers, designed specifically for high-throughput screening and genomics applications.

Strategic partnerships are emerging as a key factor in maintaining competitive advantage. For example, Eppendorf has entered collaborations with automation platform developers to co-design labware that seamlessly integrates with liquid handling robots, streamlining sample transfer and minimizing contamination risk. Similarly, Sartorius has partnered with pharmaceutical companies and biotech startups to co-develop custom thermoform packaging solutions that address unique sample tracking and storage demands in high-throughput drug discovery pipelines.

Material innovation is also a focal point, with companies like Greiner Bio-One introducing bio-based and recyclable thermoform products to align with laboratory sustainability goals. Their recent collaborations with life science consortia aim to standardize eco-friendly packaging formats for multi-site laboratory networks. In parallel, Bemis Company, Inc. (now part of Amcor) continues to push for closed-loop manufacturing processes, offering traceable, circular materials for laboratory packaging.

Looking ahead, the outlook for 2025 and beyond suggests further consolidation among packaging suppliers, with a focus on global scalability and cross-sector alliances—particularly as diagnostics, pharma, and contract research organizations demand ever-greater throughput and traceability. The ongoing integration of digital tracking (such as RFID and 2D barcoding) into thermoformed packaging is expected to intensify, as companies collaborate to address data integrity and supply chain transparency requirements. Collectively, these trends indicate a highly dynamic competitive environment characterized by cross-disciplinary partnerships and continuous innovation in support of high-throughput laboratory operations.

Sustainability Trends: Recyclability, Bio-Based Advances, and Compliance

Sustainability is emerging as a critical driver in the evolution of thermoform packaging for high-throughput laboratories, particularly as regulatory pressures and customer expectations intensify into 2025 and beyond. The focus is on enhancing recyclability, integrating bio-based materials, and ensuring compliance with evolving global standards.

Recyclability remains a paramount concern. Laboratory supply leaders are increasingly transitioning to mono-material thermoform trays—primarily using PET or PP—to simplify recycling streams and reduce contamination risk. Thermo Fisher Scientific has publicized efforts to use single-polymer packaging in their lab consumables, thereby enabling more efficient recycling in line with lab waste programs. Additionally, companies like SABIC are collaborating with packaging converters to deliver high-purity recycled polymers suitable for direct contact with sensitive laboratory products.

Bio-based plastics are gaining traction, responding to demands for lower carbon footprints and reduced reliance on fossil resources. Eppendorf has introduced pilot projects using bio-circular PP for lab consumables and packaging, and anticipates scaling these solutions in 2025. Similarly, Sartorius reports ongoing R&D into biopolymer-based thermoforming films, targeting both primary and secondary packaging applications. These initiatives are bolstered by advances in material science, with companies such as NatureWorks supplying PLA (polylactic acid) resins that meet stringent laboratory purity standards.

Compliance is a non-negotiable aspect, especially as regulations like the EU’s Packaging and Packaging Waste Regulation (PPWR) and U.S. state-level mandates are set to tighten through 2025. Laboratory packaging must not only ensure product integrity but also satisfy requirements for recyclability, chemical safety, and labeling. Leading suppliers, including Corning, are proactively publishing environmental impact data and third-party certifications for their packaging formats to facilitate compliance for laboratory customers globally.

Looking ahead, sustainability in thermoform packaging for high-throughput labs is expected to advance rapidly. Industry participants are forming cross-sector alliances to tackle recycling logistics and scale-up bio-based alternatives. The sector is also preparing for digital traceability requirements—such as QR-coded packaging for material origin and end-of-life information—anticipating both regulatory and customer-driven demands. As a result, laboratories opting for next-generation thermoform packaging can expect enhanced sustainability credentials, streamlined compliance, and improved alignment with institutional environmental goals by 2025 and in the following years.

Future Outlook: Technology Roadmap and Disruptive Innovations

Thermoform packaging is poised for significant transformation in high-throughput laboratory settings over 2025 and the coming years, driven by the convergence of automation, sustainability mandates, and digital integration. Laboratories processing high sample volumes—such as those in diagnostics, pharmaceuticals, and genomics—are increasingly reliant on precision thermoformed trays and blister packs for sample identification, contamination control, and robotic compatibility. Looking ahead, several disruptive innovations and strategic shifts are expected to redefine the sector’s technology roadmap.

One major trend is the integration of smart features directly into thermoform packaging. RFID and QR code-enabled trays are gaining traction, enabling real-time sample tracking and improved inventory management. Companies like Thermo Fisher Scientific are already incorporating data-matrix codes onto consumables to streamline laboratory automation and traceability. By 2025 and beyond, expect wider adoption of embedded sensors and digital identifiers for seamless compatibility with laboratory information management systems (LIMS).

Sustainability is another core driver shaping future innovations. High-throughput labs are under mounting pressure to reduce single-use plastics and carbon footprints. Manufacturers such as SABIC are developing advanced recyclable polymers and bio-based feedstocks tailored for thermoforming processes, aligning with global sustainability targets and the circular economy. The next few years are likely to see commercial-scale launches of mono-material thermoform trays that facilitate closed-loop recycling—without compromising barrier properties or automation performance.

Automation-ready packaging is also a focal point. As robotic sample handling and automated storage systems become standard, the tolerance and dimensional stability of thermoformed packaging must improve. Gerresheimer and other leading suppliers are investing in precision tooling and quality control systems to deliver ultra-consistent trays that minimize machine downtime. Over the near term, digital twins and AI-driven design optimization are expected to further accelerate the prototyping and validation of new formats for high-throughput workflows.

Finally, regulatory alignment and standardization will play a key role in shaping the future landscape. Industry bodies such as European Bioplastics are actively engaged in developing guidelines for the adoption of sustainable materials and harmonized packaging dimensions, helping laboratories navigate compliance and interoperability challenges.

In summary, the outlook for thermoform packaging in high-throughput laboratories is defined by rapid digitization, greener material science, and tighter integration with laboratory automation—all of which are set to accelerate through 2025 and the years ahead.

2025’s Game-Changer: How Thermoform Packaging Is Streamlining High-Throughput Laboratories—Profit, Precision, and the Future Unveiled

ByQuinn Parker

Thermoform Packaging Revolution: What Will Transform High-Throughput Labs by 2025–2030?

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