Dordan Manufacturing specializes in the design and manufacture of custom thermoformed trays like dunnage trays, medical trays, and insert trays. 

Above: Thermoformed dunnage tray protects and moves products through the supply chain, offering shipping & assembly efficiencies

As a fourth-generation, family-owned thermoforming company with over 63 years of experience, Dordan offers end-to-end tray development — from thermoform tray design and tooling to in-house manufacturing and cleanroom thermoforming. 

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 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: Our medical tray packaging protects and maintains the safety and efficacy of medical devices.. 

Plastic Insert Trays for Retail: Custom plastic inserts enhance product presentation and security inside retail packaging. 

Above: Plastic insert tray orients and displays product at retail 

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, thermoforming, and cleanroom manufacturing under one roof.

• Custom Tray Design: Using Siemens NX CAD our engineers develop high-performance thermoform tray designs optimized for usability, automation compatibility, and cost-efficiency.

• Prototype & Production Tooling: NX CAM software is used to program the CNC 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 precision tooling and strict quality control.

• Plastics Thermoforming: We have 14 thermoforming lines with 2 dedicated lines in the cleanroom.

• ISO Class 8 Cleanroom Manufacturing: For applications requiring particulate-controlled packaging, Dordan offers cleanroom thermoforming certified to ISO Class 8  standards.

 

Cleanroom Manufacturing for Thermoformed Trays

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Our ISO Class 8 cleanroom is designed to meet the cleanliness standards required for medical device packaging.

Above: Sterile medical kit to protect and organize critical devices and instruments

Features of our cleanroom facility:

• Advanced Thermoforming Equipment: Equipped with Keifel Speedformers, our cleanroom facilitates automated forming, cutting, stripping, and stacking processes, ensuring the production of defect-free products. 

• Environmental Control: The cleanroom maintains strict particulate and bioburden control, with continuous monitoring to comply with ISO Class 8 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. 

Thermoform Tray Quality Assurance

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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.

What Sets Us Apart

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63 Years of Custom Thermoforming Experience

Fully Integrated US Supplier 

4th Generation Family-Owned

IRisk-Based Engineering & Design for Manufacturing

Request a Quote 

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Contact Us or Request a Quote for custom thermoformed trays.