Procedural & Surgical Kits | Custom Thermoformed Medical Kits

Dordan designs and manufactures custom procedural and surgical kits that streamline practitioner workflows, reduce contamination risk, and meet the industry's requirements for cleanliness, safety, and usability.

Above: Medical procedural kit organizes and securely contains surgical devices and components

Dordan has 63-years of custom thermoforming experience, applying a risk-based approach to surgical kit design that results in the production of consistently high-quality medical kit packaging.

What Are Medical Procedural Kits?

Medical procedural kits are packaging systems that contain all instruments and components needed for a surgical or clinical procedure. Each kit is engineered for ease of use, sterility, and intuitive access, improving operational efficiency for healthcare professionals.

Dordan’s thermoformed trays, lids, and inserts are:

• Designed for intuitive product placement and orientation

• Manufactured with snap-fit, press-fit, or friction-fit cavities

• Optimized for finger access to support fast, safe device removal

• Available for production in ISO Class 8 cleanroom

Surgical & Procedural Kit Configurations

Procedural kits come in different formats, depending on the application. 

Above: Non-sterile surgical tray for organizing instruments

Types of kit formats offered:

Tray + Snap-On or Press-Fit Lid: Ideal for non-sterile medical kits; simple fulfillment process with no secondary sealing required; rigid lid protects contents during storage and transport.

Tray + Lid Inside Tyvek Pouch: Suitable for sterilized kits without heat sealing equipment; offers clean barrier protection; no heat seal tooling investment required

Tray + Heat-Sealed Tyvek Lidstock: Provides peel-open sterile packaging; easy opening for healthcare professionals; Supports ETO, gamma, or steam sterilization.

Full-Service In-House Medical Kit Development

By handling the full medical kit development process internally, Dordan eliminates the risk of translation errors between design, tooling, and manufacturing. This ensures consistency, fast turnaround, and optimal quality from prototype to production.

Dordan provides end-to-end procedural kit manufacturing, including:

• Siemens NX Packaging Design: Dordan utilizes NX for the design and development of its medical kit packaging. We employ a risk-based approach to package design with design for manufacturing principles. Dordan's design process is structured by its ISO 9001:2015 and ISO 13485:2016 certified quality management system, which ensures the design can be consistently produced to high-quality. 

• NX CAM/CNC Tooling: Programmed and built in house by the same team of packaging engineers that developed the package design, allowing for more intelligent quality control and rapid iterations.

• Thermoforming: Appropriate for less-critical procedural kits for non sterile devices and instruments. Managed by Dordan's ISO 9001:2015 certification for the on-time delivery of defect free products.

• ISO Class 8 Cleanroom: This fully enclosed and complete hardwall space monitors and minimizes the level of particulate and bio burdens in the production environment. The cleanroom is ideal for manufacturing procedural and surgical kits that protect critical medical devices.  r

• ISO 9001:2015 and ISO 13485:2016: Dordan's quality management system is the foundation of all procedural kit packaging projects, ensuring that each step of the packaging developmental process is efficient and transparent.

Above: CNC machine for generating medical procedural kit thermoform tooling

Cleanroom Manufacturing for Surgical & Procedural Kits

Packaging for surgical and procedural kits demands cleanliness, precision, and process control. That’s why Dordan manufactures this packaging in an ISO Class 8 cleanroom designed to meet the requirements of the medical industry.

Above: Cleanroom thermoforming of procedural medical kits