Dordan Manufacturing specializes in the design and production of custom thermoformed trays for a wide range of industries, including medical, industrial, automotive, electronics, and consumer. As a fourth-generation, family-owned thermoforming company with over 62 years of experience, Dordan offers end-to-end tray development — from thermoform tray design and tooling to in-house manufacturing and cleanroom thermoforming. 

Key Features of Thermoformed Trays

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• Customizable Design: Tailored to fit unique product shapes and sizes, ensuring optimal protection and organization.

• Material Efficiency: Utilizes only the necessary amount of plastic, reducing waste and material costs.

• Cost-Effective: Lower tooling and production costs compared to other molding processes, especially for medium to high-volume runs.

• Lightweight and Durable: Easy to handle while providing adequate protection, reducing shipping costs and product damage.

• Recyclable Materials: Often made from recyclable plastics, supporting sustainability efforts and environmental responsibility.

Thermoformed Tray Packaging Solutions

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Our custom plastic trays are engineered to protect your products during storage, shipping, handling, assembly, and retail display.

We Offer:

Thermoformed Dunnage & Assembly Trays: Designed for manual or robotic handling, our industrial dunnage trays are optimized for shipping efficiency and assembly line integration. These trays reduce damage during transit and increase throughput in automated processes. Component handling trays offer precision-fit cavities and locating features that interface with automated equipment.

Thermoformed Medical Trays & Kits: Produced in our ISO Class 8 cleanroom, our medical device and surgical trays ensure the sterility, safety, and integrity of sensitive devices. Ideal for procedural kits, sterile packaging, and procedural workflows.

Plastic Insert Trays for Retail: Custom plastic inserts enhance product presentation and security inside retail packaging. Ideal for consumer electronics, cosmetics, and health & wellness products.

Complete In-House Design, Tooling & Manufacturing

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Dordan offers a fully integrated approach to thermoformed tray production—combining in-house design, tooling, and thermoforming, and cleanroom manufacturing under one roof for greater speed, precision, and control.

• Custom Tray Design: Using Siemens NX Solid Modeling and NX CAM/CNC software, we manage the entire packaging development process. Our engineers develop high-performance thermoformed tray designs optimized for usability, automation compatibility, and cost-efficiency.

• CNC Tool Path Programming: NX CAM software is used to program tool paths for both prototype and production tooling, ensuring accurate translation from digital model to physical form.

• Tooling Fabrication & Component Assembly: All tooling is CNC-machined in-house, including form tools, trim dies, plug assists, and support components—enabling rapid iteration and strict quality control.

• Precision Thermoforming: Our thermoforming operations are equipped with state-of-the-art equipment, capable of producing complex tray geometries with tight tolerances and repeatable consistency.

• ISO Class 8 Cleanroom manufacturing: For applications requiring sterile or particulate-controlled packaging, Dordan offers cleanroom thermoforming certified to ISO 14644 air cleanliness standards.

Markets We Serve

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Dordan’s custom thermoformed trays are engineered to support high-performance packaging needs across a variety of industries. Whether you're handling fragile medical components or heavy industrial parts, our trays are built for precision, protection, and operational efficiency.

Medical & Healthcare: We design and thermoform medical device trays, assembly trays, and procedural kits in our ISO Class 8 cleanroom. All medical trays are manufactured under our ISO 13485:2016 certified quality system to ensure sterility, compliance, and safety.

Automotive: Our automotive dunnage trays and assembly trays are optimized for durability and part protection during transport and robotic handling. Available in returnable formats, our trays integrate with automated manufacturing and kitting operations.

Electronics: Dordan’s ESD-safe thermoformed trays protect electrostatic-sensitive components during assembly and shipment. Our trays are custom-designed for PCBs, microelectronics, and device subcomponents that require secure and static-resistant packaging.

Industrial Manufacturing: We provide custom dunnage trays and shipping trays that streamline handling, protect high-value components, and support WIP workflows. Our thick-gauge options offer superior durability for heavy-duty applications.

Retail & Consumer Products: Our plastic insert trays are used in retail packaging, subscription kits, and product displays. Designed for both functionality and presentation, these trays hold items in place while enhancing shelf appeal and unboxing experiences.

In-House Tray Thermoforming Capabilities

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With 13 inline thin-gauge thermoforming machines, Dordan can manufacture low-to-high volumes of custom trays in various materials, finishes, and thicknesses.

• Robotics and custom end-of-arm tooling

• Inline cutting, stacking, and inspection modules

• Rapid prototype-to-production transitions

• Cleanroom thermoforming 

Cleanroom Manufacturing for Thermoformed Trays

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At Dordan Manufacturing, we recognize the critical importance of maintaining a contamination-controlled environment when producing thermoformed trays for sensitive applications. Our ISO Class 8 certified cleanroom is specifically designed to meet the stringent cleanliness standards required for medical device packaging and component handling.

Key Features of Our Cleanroom Facility:

• Advanced Thermoforming Equipment: Equipped with Keifel Speedformers, our cleanroom facilitates automated forming, cutting, stripping, and stacking processes, ensuring precision and efficiency in every tray produced.

• Environmental Control: The cleanroom maintains strict particulate and bioburden control, with continuous monitoring to comply with ISO 14644 standards.

• Material Handling Protocols: Dedicated gowning and material staging areas with controlled air pressure zones prevent cross-contamination during the manufacturing process.

• Sterilization Procedures: We employ terminal cleaning protocols and use FDA-certified cleaning agents to maintain a contaminant-free environment.

Tray Quality Assurance

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At Dordan, quality control isn’t an afterthought—it’s engineered into every phase of our thermoforming process. From design to delivery, our vertically integrated operation ensures full control over materials, tooling, and production, supporting both regulatory compliance and performance consistency.

Certifications & Compliance

• ISO 9001:2015 Certified: Our quality management system ensures rigorous process control, documentation, and continuous improvement across all operations.

• ISO 13485:2016 Certified: For medical and healthcare customers, we meet the strict regulatory standards required for device packaging manufacturing.

Process Controls & Validation

• First Article Inspection & Validation: Critical dimensions and functional features are verified prior to full-scale production to prevent downstream deviations.

• Process Validation: We support full validation protocols (IQ, OQ, PQ) and PPAPs for customers in regulated industries.

• CPK Analysis: In-process data is monitored using statistical process controls to ensure consistent part quality within defined tolerances.

Why Work with Dordan for Custom Thermoformed Trays?

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Application-Specific Tray Design

Request a Quote for Thermoformed Trays

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Ready to optimize your product protection or assembly line with custom thermoformed tray packaging? Contact Us or Request a Quote to get started with Dordan.