Custom Thermoformed Trays
What are Custom Thermoformed Trays?
Custom thermoformed trays are specialized plastic trays designed to securely hold, protect, and organize products during storage, transport, or display, tailored to meet specific shape and size requirements. There are different tray designs that fall under the umbrella of custom thermoformed trays. These include:
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WIP (Work in Progress)/Dunnage Material Handling Trays
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Custom Thermoformed/Insert/ Prep/ Procedure Trays
What are the differences between WIP/Dunnage Material Handling and Custom Thermoformed/Insert Trays?
While the different names given to custom thermoformed trays, does denote some distinct differences, all of these trays are manufactured via the process of custom thermoforming.
WIP - Dunnage Material Handling Trays
Trays of this nature are typically used in the B2B landscape. WIP/ Dunnage Material Handling Trays are usually of a thicker material, seeing as they need to hold many parts, which adds to the total weight the tray needs to support. WIP/ Dunnage Material Handling Trays are often used on an assembly line during the various stages of manufacturing which means that automation and robotics are a part of this manufacturing equation. As a result, these trays usually incorporate a unique “stack and rotate” feature within the tray design. This means that when the trays are empty, or not in use, that they stack together minimizing space. Alternatively when the trays are being used as intended, by turning each subsequent tray in the stack 180 degrees, a unique stacking feature is deployed. This allows for the tray above the tray below it, to act as a lid. The stack and rotate feature also prevents the trays on top from making contact with the parts in the tray below it. This prevents scuffing, abrasion or part rub.
Once the desired stack of trays has been achieved, these trays are then placed inside of a shipping carton or reusable tote.
When the fully loaded trays reach their final destination the parts are removed from the trays. The trays are then nested together and returned to the product manufacturer. This creates a closed loop system which minimizes not only waste, but the overall packaging spend.
Custom Thermoformed - Insert Trays
This is the broad umbrella which captures any tray that would be used in conjunction with a single use carton/ box, Tyvek/ Poly/ Foil lidding or a pouch. While the WIP/ Dunnage/ Material Handling Trays are often designed to hold many of the same parts, Custom Thermoformed Insert Trays are typically designed for a single part/ product or a “kit” of some type. Custom Thermoformed Insert Trays are often of a thinner material since they are more of a part/ product organizing trays as opposed to an industrial shipping, assembly or handling tray. If the tray in question is being used to hold an implant or medical device, then it is often appropriate to have those trays produced in a class 8 or class 7 cleanroom environment. Material selection would be determined based on the sealing and sterilization requirements.
Which industries or markets use WIP/ Dunnage Material Handling Trays?
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Including, but not limited to: Automotive, Aerospace or Aviation, Electronics/ Semiconductor, Injection Molding, Metal Stamping and a variety of other Industrial manufacturing applications.
Which industries or markets use Custom Thermoformed Insert Trays?
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Including, but not limited to: Convenience, Consumer Goods, Cosmetics/ Personal Care, Consumer Electronics, Food, Hardware, Healthcare/ Medical Device, Semiconductor, Toys & Games and a variety of other consumer facing industries.
