Procedural & Surgical Kits | Custom Thermoformed Medical Kits

Dordan designs and manufactures custom procedural and surgical kits. Our family-owned company provides thermoformed medical trays, lids, and inserts that streamline practitioner workflows, reduce contamination risk, and meet the requirements for cleanliness, safety, and usability.

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

We offer flexible kit formats tailored to your product and sterilization needs:

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 Medical Kit Development

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

• NX CAD Design of thermoformed kits, trays, lids, and inserts

• CNC Tooling built in-house using NX CAM

• Thermoforming for less-critical medical kit packaging

• ISO Class 8 Cleanroom Production for clean and safe packaging that ensures the sterility and efficacy of the medical components. 

• ISO 9001:2015 and ISO 13485:2016 certified for reliable and repeatable quality

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

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 a purpose-built, ISO Class 8 cleanroom designed to meet the requirements of the medical industry.

Cleanroom environment includes:

• Fully-Enclosed & Complete Hardwall Build: Environmentally controlled environment minimizes airborne particulates and bio burden agents.

• Dedicated Equipment & Tooling: Keifel thermoformers outfitted for cleanroom use and engineered with syntactic foam plug assists and heated cutting dies for optimal material control.

• Validated Workflows: Comprehensive gowning procedures, airlocks, and material segregation support ISO Class 8 protocols and reduce contamination risk.

• Routine Monitoring: Regular particulate count testing and documented sanitation cycles ensure continuous compliance with Class ISO Class 8 standards. 

What Sets Us Apart