FAQs | Plastics Thermoforming & Custom Packaging by Dordan


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Explore frequently asked questions about thermoformed packaging, packaging design and manufacturing, ISO Class 8 cleanroom thermoforming, popular materials for thermoforming and more.

As a family-owned thermoforming company with over 62 years of experience, Dordan is a trusted partner for medical, consumer, and industrial packaging.

Plastics thermoforming

What Is Plastics Thermoforming?


Plastics thermoforming is a process where roll-fed thin-gauge plastic sheet is heated to a forming temperature, shaped in a mold using vacuum, air pressure, or both, and then trimmed to create rigid packaging. This method is used to produce:

Parts are stripped from the web, automatically stacked, inspected, and packed for delivery.

What Is Thermoformed Packaging?


Thermoformed packaging includes a wide range of plastic packaging solutions:

Thermoformed packaging protects, organizes, and enhances product handling across industries.

What Materials Are Used in Thermoforming?


Dordan thermoforms a broad selection of plastic materials, including:

  • Post-consumer & post-industrial RPET

  • PETG, APET, PVC, PS, HIPS, ABS, HDPE, LDPE

  • FDA-approved and medical-grade plastics

  • Anti-static / ESD materials

  • Bio-based and compostable materials

  • Freezer-grade and flocked plastics

  • Custom color-matched materials

All materials are sourced to meet your performance, regulatory, and sustainability goals. Learn more about our sustainable packaging options. 

What Is Thermoform Design?


Dordan uses Siemens NX Solid Modeling to create detailed thermoform packaging designs, optimized for manufacturability and end-use performance.

thermoform packaging designOur engineers can:

  • Reverse-engineer physical products

  • Import customer CAD files

  • Provide photorealistic renderings and drawings

  • Deliver functional prototypes and first article validation

All designs are managed under our ISO 9001:2015 and ISO 13485:2016 certified quality system, ensuring traceability, revision control, and design retention.

 

What Is Thermoform Tooling?


Dordan’s NX CAM/CNC-machined thermoform tooling is developed in-house by the same team that designs the tray. This includes:

prototype tool
  • Prototype and production aluminum tooling

  • Assist plugs, die build-ups, and trim headers

  • End-of-arm tooling for robotic automation

All tools are maintained in a temperature-controlled warehouse and remain proprietary, customer-owned assets.

What Are Dordan’s Thermoforming Capabilities?


  • 13 inline thin-gauge plastic thermoforming machines

  • Interchangeable tooling for scheduling flexibility

  • Robotic part stripping, stacking, and inspection

  • SOP-based production workflows and quality control

  • Real-time job analysis to support continuous improvement

We design and produce medical, industrial, and consumer packaging like trays, clamshells, blisters, and dunnage trays in high volume, with short lead times and competitive pricing.

What Is ISO Class 8 Cleanroom Thermoforming?


Dordan's ISO Class 8 cleanroom is a fully enclosed, hardwall facility used to manufacture sterile and non-sterile medical packaging. Features include:

  • Advanced Keifel thermoformers for forming, cutting, and stacking

  • Real-time particulate monitoring per ISO 14644 standards

  • Controlled airflow, gowning protocols, and material staging rooms

This environment ensures compliance with regulatory and sterility requirements for medical trays, procedure kits, and device packaging.

Dordan's cleanroom

What Is Thermoform Quality Control?


Our quality management system (QMS) is certified to:

  • ISO 9001:2015 – Total quality control across all packaging types

  • ISO 13485:2016 – Specialized QMS for medical packaging design and production

Every job includes:

  • SOP-driven inspections

  • Material verification and traceability

  • Optical inspection and CPK reporting

  • Continuous process improvement

Where Is Dordan Located?


Dordan is located in Woodstock, Illinois, just outside Chicago. All packaging design, tooling, manufacturing, and cleanroom production take place in-house, under one roof. This vertical integration ensures consistent quality, fast turnaround, and responsive customer service.

 How Big Is Dordan’s Facility?


  • 50,000 sq. ft. manufacturing facility

  • 13 inline plastics thermoforming machines

  • ISO Class 8 cleanroom

  • In-house tool and die shop with CNC machining centers

  • Warehouse support for vendor-managed inventory

What Is Dordan’s History?


Founded in 1962 by Vivian and Edwin Slavin in Chicago, Dordan Manufacturing is a fourth-generation, family-owned custom thermoformer.

Timeline:

Dordan circa 1974
  • 1962: Founded in Chicago, IL

  • 1970s: Transition to high-volume thermoforming under Daniel Slavin

  • 1990s: Relocation to Woodstock, IL and facility expansion

  • 2013: Achieved ISO 9001:2015 certification

  • 2019: Built an ISO Class 8 cleanroom

  • 2024: Achieved ISO 13485:2016 certification

For over 62 years, Dordan has provided thermoformed packaging solutions for medical, industrial, and consumer markets—always proudly Made in the USA.

Related Pages


Dordan History

Dordan Library 

Medical Packaging

Industrial Packaging

Still have questions?


Contact Us or Request a Quote to speak with our packaging experts about your next project.