Made-to-Order Packaging Innovation: How Do You View the Shift from PP to PET?

Made-to-Order Drinks Boom: Packaging's Shift from PP to PET and rPET

The made-to-order beverage model, characterized by on-demand preparation and immediate consumption, has experienced rapid global growth in recent years. According to Statista, the global ready-to-drink tea market is projected to grow from approximately $120 billion in 2023 to over $180 billion by 2030, with a compound annual growth rate (CAGR) of around 6.2%. 

From Starbucks’pioneering chain coffee culture in the last century to the explosive rise of new-style tea brands across China and Southeast Asia, and the accelerated adoption of self-service kiosks and automated beverage dispensers post-pandemic, the industry continues to reshape consumer expectations around freshness, customization, convenience, and aesthetics.

Within this evolution, beverages have transcended their functional role to become social lifestyle products, while packaging has evolved beyond mere containment to become a critical extension of brand marketing, visual storytelling, and environmental responsibility. Euromonitor reports that between 2020 and 2025, the global market share for high-transparency plastic cups in ready-to-drink packaging is expected to increase by over 30%, with rPET (recycled PET) adoption steadily rising above 20% in premium markets across Europe, North America, and Asia-Pacific.

Top brands like Heytea, Luckin Coffee, Starbucks, Pret, and major Japanese convenience stores prioritize these features, driving innovation in materials, design, and eco-friendly packaging across the made-to-order beverage industry.

The Rising Potential of PET Thermoformed Packaging and the Evolution of Plastic Cups

PET thermoformed packaging is poised for strong growth, fueled by consumer demand and material innovation. According to Grand View Research, the global PET packaging market is projected to rise from $53 billion in 2023 to over $85 billion by 2030, with a CAGR of 7.2%. Beverage packaging—especially single-use PET cups—makes up a significant portion, driven by rising expectations for clarity, quality, and sustainability.

With over 90% light transmittance and excellent mechanical strength, PET resins are ideal for showcasing product aesthetics. As visual appeal becomes a key purchasing driver, brands increasingly turn to PET to capture the "aesthetic economy." At the same time, stricter environmental regulations are accelerating adoption of recyclable PET and rPET. The Ellen MacArthur Foundation notes that over 60% of plastic packaging waste enters the environment, prompting some markets in Europe and North America to exceed 30% rPET usage. Many global brands now aim for 100% rPET use within five years.

Technological advances further support this shift. Modern thermoforming lines have improved efficiency by over 20% and cut costs by around 10%. The integration of RFID and digital elements is also boosting sales conversion rates by up to 20%. PET thermoformed packaging, combining visual impact, performance, and sustainability, is emerging as a key driver of growth and differentiation in the beverage packaging sector.

Wankai New Materials offers dedicated PET resin grades optimized for thermoforming applications:
🔹 WK-821 (Intrinsic Viscosity 0.83 ± 0.015) for standard APET sheet production
🔹 WK-901 (Intrinsic Viscosity 0.87 ± 0.015) for premium-grade APET sheet

Both resins feature low acetaldehyde content, excellent molecular weight distribution, and stable processing performance. They comply with FDA and EU certifications, ensuring food safety and quality. These attributes make them ideal for producing high-clarity, mechanically robust PET cups that meet growing consumer demand for premium, sustainable beverage packaging.

Historical Evolution: From PP to PET Cups

In the single-use beverage packaging sector, plastic cups have undergone a clear material upgrade. Early-stage dominance by polypropylene (PP) cups—favored for their heat resistance, low cost, and equipment compatibility—made them the mainstream choice for hot beverages like coffee, soy milk, and milk tea. From the 1990s through 2010s, PP thermoformed cups led the market with mature processes and high production efficiency, preferred by restaurant chains and fast-moving consumer goods industries.

PET thermoformed cups emerged later, around 2015, coinciding with the rapid rise of new tea beverages, cold brew drinks, and sparkling waters. PET’s high transparency, rigidity, and excellent visual presentation gradually made it the mainstream option. PET packaging meets the demand for “high aesthetics,” visibility, and social media appeal, while its recyclability and rPET adoption offer expanding growth opportunities amid tightening environmental regulations.

The “Plastics Market Watch – Beverage Containers” report by the U.S. Plastics Industry Association (SPI) highlights that PET has become the primary material for cold beverage packaging, with an annual growth rate significantly surpassing traditional PP cups. Data from Euromonitor and Mintel show that from 2019 to 2024, the usage rate of PET clear cups in global cold beverage chains has increased by over 35%, a trend especially prominent among premium chain brands, reflecting strong consumer demand for high-quality, transparent packaging.

PP vs. PET: Packaging Evolution Driven by Made-to-Order Beverage Growth

The rapid rise of made-to-order beverages has driven a gradual shift in packaging materials from traditional polypropylene (PP) to higher-performance polyethylene terephthalate (PET) and its recycled variant, rPET. This transition is fueled not only by brands’ increasing demand for enhanced consumer experience and visual appeal but also by tightening environmental regulations and advancements in material technology.

PP Cups: Early Mainstream Material—Advantages and Limitations

PP cups, known for their low cost, high heat resistance (withstanding temperatures above 100°C), and good rigidity, became the preferred packaging choice in early ready-to-drink scenarios such as milk tea, coffee, and juices. They are compatible with heat sealing processes, ensuring safe transport for hot beverages.

However, as market expectations for packaging aesthetics and functionality rise, PP’s limitations have become evident, especially for cold drinks and complex mixed beverages:

• Low transparency: PP cups are often translucent or milky, failing to effectively showcase the rich colors and layers of the drinks;
• Limited visual appeal: They struggle to meet demands of the “appearance economy” and social media sharing;
• Surface printing constraints: Branding and graphic design are restricted, limiting personalized and high-quality communication;
• Heavy tactile feel: The thicker structure impedes conveying a light, stylish brand image.

Emerging Mainstream: PET Leads Packaging Visual Appeal and Branding

With the rise of social media and consumers’ desire for “photo-ready” experiences, PET has quickly become the preferred material for cold drink packaging due to its outstanding visual properties. PET cups offer several key advantages:

• High transparency (over 90% light transmittance), perfectly displaying drink layers, colors, and pulp details, enhancing visual attraction;
• Excellent strength and rigidity, providing good support while remaining lightweight, facilitating transport and stacking;
• Superior surface printability, supporting fine printing and labeling to empower brand personalization;
• Good sealing compatibility, fitting leak-proof lids to meet cold chain logistics and takeaway convenience needs.

Global brands like Starbucks widely use PET and rPET clear cups, highlighting eco-friendly materials and strong brand image. McDonald’s McCafé boosts beverage appeal and promotes recycled materials with PET thermoformed cups. UK’s Pret A Manger also embraces sustainable PET and rPET cups for cold drinks. These brands leverage PET’s visual and environmental advantages to strengthen recognition and lead packaging trends in the made-to-order beverage market.

How to Choose Packaging Materials? A Scientific Guide from PP to PET

From a material compatibility perspective, hot drinks like coffee and soy milk are better suited for PP cups, whose excellent heat resistance (>100°C) ensures drinking safety. Additionally, PP raw materials are cost-effective, making them suitable for brands emphasizing cost control and value.

For cold beverages such as new-style teas, fruit teas, and sparkling waters, PET or rPET cups are strongly recommended. PET boasts outstanding transparency and rigidity, clearly showcasing beverage layers, colors, and pulp details, enhancing visual appeal and social sharing potential, making it the preferred packaging for premium cold drinks.

From a brand strategy and market trend viewpoint, rising environmental demands are rapidly accelerating rPET (recycled PET) adoption. For brands with overseas export plans or corporate social responsibility commitments, using rPET not only complies with global green packaging regulations but also brings policy support, improved financing ratings, and consumer eco-recognition, becoming an essential tool for building long-term corporate value.

Overall, the industry is broadly adopting a “dual-cup strategy” for hot and cold drinks: hot drinks use PP cups, cold drinks use PET or rPET cups. Meanwhile, more brands regard packaging as a strategic resource for brand communication and sustainable development, not merely as a “container.” In the future, material selection will no longer be a simple cost or process decision but a comprehensive consideration closely tied to brand positioning, user experience, regulatory compliance, and market trust.

Conclusion

In today’s fast-evolving made-to-order beverage market, packaging goes beyond cost—it reflects brand values, engages consumers, and meets growing sustainability demands. The shift from PP to PET and rPET combines better aesthetics, innovation, and eco-responsibility. Brands that embrace this change will gain market share and build lasting loyalty. This packaging revolution is now essential for future success.