Insert Tray Manufacturer | Custom Plastic Insert Trays for Retail & Kits

Dordan Manufacturing is a plastic insert tray manufacturer with over 63 years of experience designing and thermoforming custom plastic inserts for a wide range of consumer, retail, and healthcare packaging applications.

What Are Plastic Insert Trays?

Plastic insert trays are custom thermoformed trays designed to organize, protect, and present products within outer packaging—such as cartons, clamshells, mailers, or rigid boxes. 

Key Functions of Plastic Insert Trays:

• Product Orientation & Protection: Custom cavities securely hold items in place from packaging fulfillment through retail display. 

• Presentation & Branding: Clear or colored trays elevate the visual appeal of products, helping to enhance perceived value and improve shelf presence or unboxing aesthetics.

• Material Versatility: Trays can be made from a wide range of materials—including PET, RPET, HIPS, and PVC—selected for durability, sustainability, or electrostatic discharge (ESD) properties.

Plastic Insert Tray Features

• Friction and snap-fit cavities to hold products securely

• Anti-rotation design for cylindrical items (e.g., bottles, tubes)

• Finger notches for easy removal by the end user

• Lightweight, efficient material use for sustainable packaging

• Made with recycled content, recyclable where facilities exist

Plastic Insert Tray Design & Manufacturing

Dordan is a full service insert tray supplier with in house design, tooling, and thermoforming. 

Our In Hose Capabilities Include:

• NX CAD Packaging Design: Using Siemens NX, our engineering team develops 3D models, engineering drawings, and 3D printed samples tailored to your product’s shape, handling requirements, and brand presentation goals. 

• CNC-Machined Tooling: We build all prototype and production tooling in-house. This ensures tight tolerances, short lead times, and greater control over tooling quality and lifespan.

• Thermoforming: Our thermoforming lines accommodate a wide range of materials including PET, RPET, HIPS, PVC, HDPE, and specialty ESD plastics—designed for durability, clarity, sustainability, and functional performance.

• ISO Class 8 Cleanroom Manufacturing: For healthcare, pharmaceutical, and contamination-sensitive applications, we produce insert trays in a fully enclosed, ISO Class 8 cleanroom. This environment meets the strict cleanliness standards required for medical packaging and component handling.

• ISO 9001:2015 & ISO 13485:2016 Certified: Our Quality Management System is certified for the design and production of custom thermoformed packaging, ensuring consistency, documentation, and continuous improvement across all industries we serve.

What Sets Us Apart

Fully Integrated Manufacturing in USA