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Custom insert trays

Insert trays are developed to 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

How insert trays are used in packaging

Insert tray applications

Insert trays support product organization, protection, and presentation within cartons, kits, rigid boxes, and retail packaging.

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

Integrated insert tray development

Insert tray design, tooling, and production support

Dordan supports insert tray programs through in-house design, tooling development, thermoforming, and quality control. Tray designs are developed around product dimensions, orientation, protection, packout, and packaging system requirements.

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

Plastic thermoforming

Thermoforming & Quality Control

Insert trays are thermoformed under ISO-certified production controls to support dimensional consistency, cavity definition, material performance, and repeatable manufacturing

Start your custom insert tray project

Custom insert trays engineered for product organization, protection, and efficient packout

Request a Quote Call (815) 334-0087