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

Dordan Manufacturing is a plastic insert tray manufacturer with over 62 years of experience designing and thermoforming custom plastic inserts for a wide range of consumer, retail, and healthcare 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. These trays are commonly used across industries like retail, cosmetics, healthcare, electronics, and e-commerce to enhance product protection and the unboxing experience.

Key Functions of Plastic Insert Trays:

• 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.

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

Insert Tray Applications 

Dordan provides insert trays for a diverse range of applications, including:

• Retail Insert Trays: Designed to fit seamlessly within cartons and containers, these trays enhance product visibility and shelf appeal, securely hold items in place during transit, offer customizable finishes, including clear, black, or colored plastics with matte, gloss, or textured surfaces; and, provide protection during shipping without the need for additional assembly and present an organized and professional unboxing experience for end-users.

• Healthcare and Medical Trays: Our ISO Class 8 cleanroom manufacturing ensures that insert trays meet stringent cleanliness and safety standards. 

• Cosmetics Insert Trays: Designed to display products like lipsticks, serums, and creams attractively, protect delicate items from damage, and enhance brand presentation with custom designs and finishes.

• Electronics Insert Trays: Safely house components like PCBs, semiconductors, and connectors, utilize materials with electrostatic dissipative (ESD) properties, and integrate into automated assembly and handling systems. 

Full-Service Insert Tray Manufacturing

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.

Our Capabilities Include:

• 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.

From product presentation to sterile handling, Dordan’s full-service insert tray manufacturing capabilities ensure the highest level of precision, cleanliness, and quality—every step of the way

Why Work with Dordan?

When packaging precision, product protection, and presentation matter, leading brands across industries choose Dordan to design and manufacture their custom plastic insert trays.

What Sets Us Apart

Fully Integrated Manufacturing

Custom-Engineered Fit & Function

Cleanroom Production for Healthcare

Certified Quality Systems

4th Generation Family-Owned, Service-Driven, Made in USA