Frequently Asked Questions

What is plastics thermoforming?

Thin gauge plastics thermoforming is a conversion process where roll fed plastic sheet is heated to a pliable temperature, formed to a specific shape in a thermoform tool via vacuum, air, and pressure; then, die cut to create rigid plastic packaging like clamshells, blisters, trays, and components. The thermoformed packages are then stripped from the plastic web, stacked, checked for quality, and packed for shipment to the customer.


Dordan Laser Cut V3(1)


Video of robot stripping thermoformed packaging 

What are the applications for thermoformed packaging? 

What types of plastic 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, FDA certified materials, medical grade materials, bio-based and compostable materials, freezer proof materials, flocked materials (custom color matching available); and, color matched virgin and reprocessed materials.

What end markets does Dordan provide custom thermoformed packaging to?

Dordan provides custom thermoformed packaging to the medical, healthcare, automotive, retail, cosmetic, electronics, and industrial end markets. 

Does Dordan provide food packaging?

Dordan offers FDA certified materials for direct and indirect food-contact packaging.

Does Dordan have a cleanroom for manufacturing medical packaging?

Dordan has an ISO Class 8 Cleanroom for manufacturing medical packaging. Equipped with 2019 Kiefel Speedformers utilizing best-in-class automated forming, cutting, and stripping stations, Dordan provides medical device tray packaging, medical kits, medical clamshells and containers, pharmaceutical blisters; and, medical component/assemblies dunnage and shipping trays.


Cleanroom packaging

Dordan's cleanroom for manufacturing medical packaging

Where is Dordan located?

Dordan is located in Woodstock, IL. All packaging design, tooling, thermoforming, and medical packaging is done in house. This integration allows for the production of consistently high quality thermoformed packaging in quick turnaround at competitive pricing.

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 thermoform tooling in house?

Yes, Dordan is equipped with a tool and die shop with 4 Haas CNC machining centers and the necessary ancillary equipment to produce and assemble thermoform tooling. All thermoforming tools, prototype and production, are NX CAM/CNC produced out of aircraft-quality aluminum. The same team of packaging engineers that develop the packaging design also create the thermoform tooling, allowing for more intelligent quality control as there are no translation errors between thermoform part design and production parts.

Thermoform tooling

CNC machine in Dordan's in-house tool room 

What type of thermoform packaging designs does Dordan offer?

Dordan develops Solid Model NX thermoform designs, engineering drawings, photorealistic renderings, and prototypes. Dordan is proficient with importing/exporting a variety of engineering files and formats. Dordan's packaging engineers create custom thermoform designs based on customers' requirements and expectations; then, program the CNC machines for the production of tooling; and, work with Dordan quality control and production management to oversee the manufacture of high quality thermoformed packaging that performs.

What size is Dordan Manufacturing?

Dordan Manufacturing is a 50,000 square-foot facility equipped with 12 thermoforming machines that have the capacity to convert 80-million pounds of material annually; an ISO Class 8 Cleanroom with 2019 Kiefel Speedformers for manufacturing medical device packaging; an in house tool and die shop with 4 VF Series CNC machining centers; automated stripping and stacking robotics; and, warehousing for vendor managed inventory.

Photo 10-1

Dordan's plastic thermoforming machines

Does Dordan have a certified Quality Management System?

Dordan is ISO 9001:2015 certified for the design, manufacture, and distribution of custom thermoformed products and packaging.