Custom thermoformed packaging

Custom trays, inserts and lids.

Develop thermoformed packaging around your product. See how the lid, insert and base work together in the structure example below.

Discuss your project See mold details

Lid, insert and base

Lid above, eight-position insert in the middle, base below.

Overview

Define the product and packing method.

Share the dimensions, count and the way the product is filled, stored and handled.

What product needs packaging?

Add the count or measurements if you know them.

Describe your product in the enquiry form.

Packaging examples

Open a photo to inspect its compartments, rim and closure.

5 images

**Open and closed fruit packs**Rectangular packs, a round cup and a divided tray show different shapes to discuss.Which lid shape leaves room for your fruit?Share fruit size and fill weight, then check the closed pack with the actual contents.

**Tall and shallow packaging formats**The display shows different pack heights, lid profiles and tray shapes.How much height does the filled pack need?Compare shallow and tall formats against your product and outer carton dimensions.

**Round packs and divided trays**Circular containers and trays show open, lidded and divided formats.Should the contents stay together or in separate sections?Describe the mix and portion size to discuss an open or divided tray.

**Printed cups and lid shapes**Cups are shown with flat and domed lids. Artwork and lid fit depend on the project.Does the cup need a flat lid or space under a dome?Describe the contents and opening needed; check the chosen lid on the cup sample.

**Clear cups with separate lids**Cup heights and lid shapes can be compared here; the exact pairing needs a fit check.Which cup rim and lid need to fit together?Provide both references or samples so the pairing can be checked.

Project view

Review the shape where it matters.

Consider cavity depth, support points, walls, openings and rim fit together.

In the mold photos below, open “Rounded cavities and separators”. Select the two numbered points to review a cavity wall and the outer edge. The other views show separate layouts, machining and polishing.

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Rounded cavities and separatorsA close view of the cavity walls, central divider and surrounding edge.How should the cavities and central divider fit your product?Bring the product dimensions; review contact and clearance with a packed sample.

Select a number on the mold photo to review that area.

Cavity wall
Where does the product need support, and where should there be clearance?
Share the product shape and size range. Mark the contact areas you want to check on a sample.
Outer edge
Which outside dimensions must stay fixed for the complete pack?
Specify the required footprint and adjacent parts. Check the fit with the intended cover or box using the matching components.

The photo shows visible tool geometry. Review dimensions and final contact against your project drawing and a filled sample.

Mold shapes and surface work

Look at cavity layouts, edges, machining and polishing. Dimensions and fit are checked against the drawing and sample for your project.

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Tray shape at the forming stationA rectangular outline, rounded recesses and raised separators are visible in the sheet.Where should each item sit inside the tray?Describe the product size and count to review the recesses and raised separators.

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Tool plates on the workbenchSeveral plates show how repeated shapes are arranged across the tool.Which outline and repeated details does your pack need?Mark the shape to discuss on your reference photo or drawing.

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Different cavity layoutsStored tools show rounded, divided and open cavity shapes.Does your product need individual pockets or an open tray?Compare the visible layouts, then describe how you will arrange the contents.

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Machining a tool surfaceA cutting tool works over repeated rectangular cavities.Which cavity edges and raised details need to change?Mark those areas on a drawing before discussing changes to the tool.

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Polishing a cavity surfaceA handheld tool works inside a cavity near its raised features and edge.Which surfaces will touch or display your product?Identify those areas; agree the finish using a physical sample.

Overview

Check function as well as shape.

Review filling access, closure, product contact and stacking using the proposed structure.

Filling

Closing

Use

Describe your product in the enquiry form.

Overview

Review your project details.

Check the product and use conditions you have entered. In the enquiry form, you can add material preferences and questions about tooling.

Prepared inquiry details

This summary follows your answers. You can edit it in the enquiry form.

Thermoformed packaging project
Product: To confirm
Filling: To confirm
Closing: To confirm
Use: To confirm

Materials, dimensions and fit are reviewed with your product and use conditions.

Overview

Choose a practical starting point.

Compare an existing format, a focused adaptation or a new mold according to the required changes.

Check a reference structure

You have a pack or drawing that could fit your product.

What to bring: The exact reference, its dimensions and material, plus your product measurements.

What to review: Compare product fit, closure, stacking and the outer carton.

Review output to agree: A fit checklist showing what matches, what differs and what needs a sample check.

Discuss a specific modification

You have a starting structure and can identify what needs to change.

What to bring: The starting reference, the requested changes and the features that must stay fixed.

What to review: Check how each change affects the structure, tooling and packing process.

Review output to agree: A change list, tooling questions and checks for the revised sample.

Assess a new mold

Your requirements need a new structure, or there is no suitable reference to compare.

What to bring: Product measurements or a drawing, packing requirements and the functions to test.

What to review: Discuss the proposed structure, tooling scope, ownership and sample revisions.

Review output to agree: A proposed tooling scope and sample plan, with cost and timing still to agree.

Unsure where to start? Prepare your product details and describe what you need to resolve.

Review my details See the development process

Process

Read the structure before checking the sample.

Review dimensions, filling, closure and handling with a sample appropriate to the feature being checked.

**Top view: positions and footprint**Eight fruit positions follow a 3–2–3 arrangement. The lid, insert and base have separate outlines; the dimension lines show which footprint belongs to each part.

**Side view: support and height**The side views show the shallow lid, the shaped insert and the deeper base. They make the vertical relationship visible before fruit clearance and closure are checked with a filled sample.

These drawings show a structure example. For your product, use the sample to confirm fruit contact, closure fit and the complete pack.

See how to check the sample

Overview

See the tooling and manufacturing context.

Connect the structural discussion with the tooling and production requirements for your pack.

The photos below show sheet rolls, feed and production equipment. Read them alongside the packaging shapes and tool surfaces above; they are separate references, not a verified sequence from one project.

Review packaging shapes Review tools and surfaces

Production equipment

Views of the line and its working parts provide manufacturing context. A project sample is used to check the resulting pack.

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**Raised equipment covers**The open covers reveal the bed and rollers below.

**Guarded equipment section**Yellow guards and control buttons sit alongside the rest of the line.

**Covered stations along the line**The sheet path, covered sections and operator controls are visible together.

**Production line, side view**A wider view of the equipment panels and access aisle.

**Equipment and working space**Open covers, a guarded station and the aisle appear in the same view.

**Roller assembly, close view**The rollers, end guards and frame can be seen at close range.

**Sheet path and guide frame**The clear sheet crosses the foreground below the overhead guide rollers.

**Roller assembly from the front**The sheet, front roller and machine frame are visible together.

Sheet rolls and feed

These photos show storage and the sheet path at the equipment. Material grade and thickness are agreed for the intended pack.

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**Sheet rolls in storage**Wrapped rolls rest on supports above the floor.

**Roll ends and wrapping**The roll cores and protective wrapping are visible from the aisle.

**Sheet storage, front view**A closer view of the rolls and the supports beneath them.

**Clear sheet across the rollers**The flat sheet passes over the visible rollers at the machine.

**Sheet path at the machine**A closer view of the clear sheet between the roller assemblies.

Thermoforming machine on the floor

This photo shows the machine and surrounding equipment; use the packaging views above to discuss the pack shape.

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**Thermoforming machine**An enclosed machine and its adjacent handling equipment on the production floor.

Bring your product into the discussion.

Send a drawing, a reference pack or a description of what needs to change.

Start a packaging brief

Packaging examples

Cavity wall

Outer edge

Mold shapes and surface work

Check a reference structure

Discuss a specific modification

Assess a new mold

Production equipment

Sheet rolls and feed

Thermoforming machine on the floor

Bring your product into the discussion.