In this project, a manufacturer of medical devices needed us to engineer a packaging system for custom PETG trays and covers that would be used in the operating room during surgeries. The package required an ergonomic design to allow for easy opening during use. At Plastiform we are a full service provider of engineering, design, and complete thermoforming services, specializing in turn-key solutions such as the project highlighted here.

From the customers design requirements, we developed a concept and prototype which utilizes an inner tray that nests inside an outer tray, with a lid that covers the contents. The lid included vertical lugs which held the product in the tray, with primary and secondary perimeter surfaces, and tabs with finger clearance corners to allow for easy removal of the Tyvek seal. The finished product measured 10.25″ in length, 5.00″ in width, with material thickness of .035″.

The prototype and production run of 500 pieces was completed on a single station thermo-former that utilizes a portable laminar flow hood to reduce packaging contamination. This capability also allowed us to achieve tolerances of ±.002″.

Fully inspected and tested, this project, from concept to delivery, was completed in just 6 weeks. For more information on this project or our processes used to manufacture custom handling trays, see the table below or contact us directly.


Results-Oriented Packaging Solutions

We know what works for over 50 years and we’ll repeat the same results for you. We know what kind of packaging:

  • Secures retailers’ approval
  • Attracts your target customers
  • Leaps over your competitors
  • Drives down shipping & warehousing costs
  • Prevents product damages due to shipping and mishandling
  • Generates more revenue and profit

Massive Production Capacity & Range

With Plastiform, there’s no project that’s too big or too small.

From prototyping five samples, to short runs, to long runs in the millions. Plastiform has the capacity to handle your thermoform production requirements.

We boast 11 roll-fed, high volume production lines capable of running 24/7, plus 10 short run lines.

We can deal with your massive production requirements and complicated parts with no problem!

Industry-Grade Supply Chain Support & Solutions

We have the warehouse capacity, technical team, and advanced systems & machinery to help you with your supply chain support problems. Whether it’s Make & Hold, JIT Delivery, or Seasonal Production, we have the manpower, the experience, and the equipment to meet your most complicated requirements. We work hard to make it easy to do business with Plastiform!


ISO - Medical Tray with Lid
SPE - Medical Tray with Lid
Institue of Packaging Professionals - Medical Tray with Lid