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 applications.
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. These trays are commonly used across industries like retail, cosmetics, healthcare, electronics, and e-commerce to enhance product protection and the unboxing experience.
Product Separation & Protection: Custom cavities securely hold individual items in place, preventing movement, breakage, and cosmetic damage during shipping or handling.
Presentation & Branding: Clear or custom-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.
Custom-Fit Engineering: Each tray is designed using 3D modeling software to match the dimensions and functional requirements of the product it’s intended to hold—ensuring a snug, professional fit.
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
Dordan is a vertically integrated manufacturer of custom plastic insert trays, offering end-to-end solutions under one roof—from concept through production. With over 62 years of thermoforming expertise and a fully in-house operation, we deliver packaging solutions that are engineered for precision, protection, and performance.
NX CAD Packaging Design: Using Siemens NX, our engineering team develops 3D models tailored to your product’s shape, handling requirements, and brand presentation goals. This allows for precise tray design optimized for both protection and appearance.
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.
Why Work with Dordan?
What Sets Us Apart
Fully Integrated Manufacturing in USA
Custom-Engineered Fit & Function
Certified Quality Systems
4th Generation Family-Owned Since 1962
Request a Quote for Plastic Insert Trays
Whether you're launching a new consumer product or need precision packaging for medical components, Dordan’s plastic insert trays deliver performance, protection, and presentation. Request a Quote or Contact Us today to get started.