Frequently Asked Questions

What is plastics thermoforming?

Plastics thermoforming is a conversion process where a plastic sheet is heated to a pliable forming temperature, formed to a specific shape in a mold, and trimmed to create a usable product. The sheet, or "film" when referring to thinner gauges and certain material types, is heated in an oven to a high enough temperature that it can be stretched into or onto a mold and cooled to a finished shape.



What is thermoformed packaging?

Plastic thermoformed packaging is thin-gauge, rigid plastic parts and containers that protect and display products at retail; facilitate assembly/production/shipping efficiencies; integrate with robotics/automated platforms; and, serve custom functional performance requirements for a variety of end-markets. 

Examples of plastic thermoformed packaging for retail include: plastic clamshells, blisters, insert trays, point-of-purchase display trays, bifold packaging, and sustainable packaging.

Examples of functional thermoformed packaging for industrial applications include work-in-process trays / dunnage trays for automation and manual filling operations; shipping and supply-chain trays to move components, assemblies, sub-assemblies, and products throughout a facility, between facilities, and between supply-chain partners; and, custom thermoformed components.


What types of plastic packaging materials do you thermoform?

100% post-consumer RPET (varying concentrations of post-consumer content available), post-industrial RPET, APET/PETE, PETG, RPETG, anti-stat/ESD materials, PVC, PS, ABS, PP, PE, HIPS, RHIPS, HDPE, RHDPE, LDPE, medical-grade materials, bio-based materials, compostable materials, FDA-certified materials, freezer-proof certified materials, flocked materials (custom color-matching available); color-matched virgin and reprocessed materials.


What end-markets does Dordan provide custom thermoformed packaging solutions to?

As custom thermoformers, Dordan provides custom thermoformed product and packaging solutions to many end-markets, including:

Does Dordan provide food packaging?

Dordan has experience designing and manufacturing custom thermoformed food packaging solutions in a variety of food-grade and FDA-certified materials. Dordan's ISO 9001:2015 certified quality management system facilitates the manufacture of safe and clean direct, and non-direct, food-contact thermoformed packaging.

Does Dordan provide medical device packaging solutions?

Dordan to offer ISO Class 8 Cleanroom medical packaging for FDA Class 1, Class II, and Class III Medical Devices, spring 2019.

ISO 9001:2015 certified and ISO 13485-certification pursuant for the design, manufacture, and distribution of custom thermoformed medical packaging solutions.

Does Dordan manufacture custom thermoformed packaging in America?

Dordan manufactures custom thermoformed packaging in Woodstock, IL. All thermoform package design and engineering, tooling, and plastics thermoforming is done in-house. This full-service integration allows for the production of consistently high-quality thermoformed parts and packaging in quick turn-time at competitive pricing.


Does Dordan Manufacturing offer contract packaging and/or fulfillment services?

Dordan is an engineering-centric designer and manufacturer of custom thermoformed product and packaging solutions. We do not offer contract packaging services, but work with a qualified network of partners to aid our clients in meeting their procurement and supply chain needs.

Does Dordan offer easy-open clamshell packaging?

Yes, Dordan offers easy-open clamshell packaging.

Does Dordan Manufacturing manage inventory?

Dordan offers vendor-managed inventory.

Does Dordan design and machine its own thermoform tooling?

Yes, all thermoform tools, prototype and production, are CNC-machined out of air-craft-quality aluminum in-house at Dordan. The same team of packaging engineers that develop the thermoform design also create the production tooling, allowing for intelligent quality-control.

What type of thermoform packaging design services does Dordan offer?

Dordan's packaging engineers create custom thermoform designs from scratch, collaborate with customers to modify/enhance existing thermoform designs, and/or replicate thermoform designs. Dordan is proficient with importing/exporting a variety of engineering files and formats. Dordan offers different thermoform packaging design formats, including engineer drawings, 3D animations, photorealistic renderings, prototypes, etc.


What size is Dordan and where is it located?

Dordan Manufacturing is a 50,000 square-foot facility equipped with12 thin-gauge in-line plastics thermoforming machines, an in-house tool and die shop with 4 CNC machining centers, and warehousing for vendor managed inventory and tooling storage. 

Dordan is located about 60-miles northwest of Chicago in Woodstock, IL. Woodstock is the site of Bill Murray's Groundhog Day film setting.

Dordan to have a fully-enclosed hardwall construction ISO Class 8 Cleanroom, spring 2019.