A process and apparatus for forming three-dimensional containers from a continuous flat web of paper, coated paper, paper board, or laminated paper board ("paper") in which the paper is first scored to define the shape of the container and, thereafter, the scored stock is simultaneously cut and formed into a container. Containers so produced have improved uniformity. The apparatus is less expensive and easier to operate than conventional equipment, and it is easier to change from one style of tray to another. The apparatus also makes possible tray styles which could not be made with machines which cut and transfer paper blanks to a separate forming station.

A die system (10) for cutting a piece of sheet stock (11) to create a blank and forming the blank to create a container includes first and second mating die halves (56, 96) and a cutting punch (68). The first and second mating die halves (56, 96) are configured to move together to form the container from the blank. The cutting punch (68) extends about the first die half (56) and is movable therewith. The cutting punch (68) is configured to cut the piece of sheet stock (11) to create the blank. Movement of the die halves (56, 96) together causes the cutting punch (68) to cut the blank from the piece of sheet stock (11) and further movement of the die halves (56, 96) together causes the first and second die halves (56, 96) to form the container from the blank.