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Thermoformed insert trays

Insert trays secure products within outer packaging, supporting consistent orientation, protection, and efficient handling

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Thermoformed insert tray
Custom plastic insert tray

Insert trays engineered around product design

Thermoformed insert trays create dedicated cavities that organize, position, and protect products within cartons, rigid boxes, kits, and retail packaging. Tray layouts are developed around product dimensions, handling requirements, and presentation objectives.

  • Custom cavity layouts for product positioning
  • Organized presentation within outer packaging
  • Reduced movement during shipping and handling
  • Compatible with cartons, rigid boxes, and kits
  • Features such as nesting, anti-rotation, and finger access

Insert tray applications

Custom insert trays for retail & consumer packaging applications

Dordan designs and manufactures thermoformed insert trays for a variety of packaging applications, including consumer product sets, cosmetics and personal care products, electronics, retail gift boxes, and industrial kits. Each application has unique requirements for product arrangement, protection, and presentation.

Cosmetics insert tray

Outer Packaging Integration

Insert trays are designed to fit within cartons, rigid boxes, and mailers, creating a structured presentation that supports both protection and branding

Thermoformed insert tray

Multi-Item Organization

Insert trays organize multiple components within a single package, keeping items separated, visible, and easy to access

Custom plastic insert tray

Product Protection & Retention

Custom cavities hold products securely in place during packing, shipping, and handling, reducing movement, damage, and misalignment

Insert tray design & manufacturing

Design, tooling, and production under one roof

Dordan's vertically integrated approach brings engineering, CNC tooling, and thermoforming together under one roof. This allows our teams to coordinate insert tray design, tooling development, and production requirements efficiently while maintaining consistency throughout the manufacturing process.

Insert tray design and prototyping

Design & Engineering

Insert tray designs are developed in Siemens NX around product geometry, cavity layout, orientation, protection, handling, and packout requirements

CNC machine for insert tray tooling

In-House Tooling Development

Prototype and production tooling is CNC-machined in-house to support cavity accuracy, forming consistency, product fit, and efficient design revisions

Insert tray thermoforming company

Insert Tray Thermoforming

Dordan thermoforms custom insert trays with precise cavity geometries, consistent material distribution, and repeatable production quality

ISO 9001 certified thermoformer

Insert Tray Quality Control

Our ISO 9001:2015-certified quality management system supports inspection of critical dimensions, cavity geometry, and product fit to ensure insert trays meet customer specifications

Let's scope your insert tray project

Share your product dimensions and protection requirements — even if specs aren't finalized — and a specialist will review your project and follow up same-day. No automated quotes, no pressure.

Request a Quote Call (815) 334-0087