Thermoformed trays and boxes
This technique uses heat and pressure to shape a sheet of heated material into a landscape determined by the mould. The reverse also works: heating a plastic foil to transform it into a mould by vacuuming. Subsequently, the resulting parts are separated from the rest of the film through cutting.
Thermoformed trays have a specific design defined by the limitations of this process. The individual compartments can be formed to follow the product’s shape precisely down to the smallest detail. The spaces for stacking or removing parts without the “vacuum effect” are helpful for easy manipulation.
Thermoformed containers have a low deviation tolerance, and the shapes are detailed.
They are reliable products, resistant to breakage and heavy loads.
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Reusable thermoformed trays
Reusable thermoformed trays can be produced in any shape for various products, from small or light to large or heavy products.
They are used in the automotive and electronics industries for sensitive parts, aerospace, precision equipment components, medical optics, etc.
The parts are placed in cavities that follow their shape closely for excellent transport conditions.
Handling when loading and unloading standard thermoformed trays are very quick, as is the reception upon delivery.
They can be stacked and placed in a larger returnable package – KLT boxes, VDA, injected containers etc. or they can sit individually in returnable packaging. The optimum solution depends on the application.
Standard thermoformed packaging can be made of PET, PET-G, ABS, HIPS, or conductive/dissipative ESD materials.
They can be disposable or returnable. Reusable trays are usually designed to be nested with a 180° rotation. This greatly improves return transport and storage.
Optionally, cutouts or TPU coatings can protect very sensitive parts from scratches caused by moving parts during transport.
They can be cleaned in washing machines.
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Thermoformed blister trays
Thermoformed blister trays have individual cavities or capsules in which the same products are usually placed.
The blister is a thermoformed PVC alveolus, which allows viewing the product through the transparent surface of the package.
They are wholly customized packaging used to transport large series of small and medium-sized parts, which need protection and cannot be packed in bulk. The cavities are precisely formed according to the pieces to maintain their position and protect them from surrounding forces.
The trays can be produced from sheets of PET, PS, HIPS, ABS or PP as thick as necessary to support the total weight of the parts in the tray with minimum material consumption. This maintains low costs in production and transport. They can also be made of sheets with ESD properties. The trays are usually arranged in layers inside injected plastic boxes.
They are mainly used in the automotive and electronics industries when return trips for the packaging are not viable, or costs exceed the price of new trays.
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Heavy duty thermoformed trays
This line of trays is specially designed to return stacked on pallets without the help of plastic or pallet boxes.
Heavy-duty trays are safe and efficient for transporting heavy loads and large parts, e.g. conveyor parts, high-pressure pumps, fuel pumps, piping, housings etc. They are often used with robotic arms (Kuka, Fanuc, Yaskawa) because they provide the necessary precision.
These heavy-duty trays ensure both high density and safe separation of the products.
They are cost-effective, robust, and withstand repeated use.
Equipped with double frames for reinforcement, they cope with high stack weights and ensure stacking stability. They can be produced with edges to accommodate lids or other protections if required.
Even if the materials are of superior quality to withstand intensive use, the trays are lightweight, thus optimizing transport costs.
They can be separated from the container in which they are placed, and they can be washed to remove residues as efficiently as possible and not contaminate parts on following transports. After washing and drying, the container and heavy-duty tray are reassembled for subsequent uses.
Trays can be used with wooden or plastic pallets. The top row is covered with a lid. A non-slip protective sheet on the pallet can significantly improve stability. Suitable for washing in plastic shuttle washing machines.
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Twin sheet thermoformed battery pack cases
Special thermoformed packaging for batteries and engines is mainly used in the automotive sector but is just as valuable for the heavy machines industry.
It can be used for standard car batteries or hybrid vehicle batteries.
Nestable when empty and resistant when used, HDPE twin sheet trays are complete mini containers for transport (pallet + lid or pallet + interlayer + cover).
Their thoughtful design that allows nesting highly increases warehouse storage capacity using less space. For the return transport, the costs are visibly improved due to the maximization of the number of pieces per stack and space optimization through a reduced number of stacks.
Compared to other packaging solutions used in the industry, these thermoformed twin sheet containers have a much lower weight-to-resistance ratio, which means decreased transport costs and an increased level of maneuverability by operators. They are easy to use, robust and long-lasting.
Types of battery packaging we have experienced:
- Thermoformed transport containers for lithium-ion batteries (UN certified)
- Complete encapsulated packaging for batteries
- Packaging for refurbished batteries
- Packaging for standard car batteries – batteries are placed on a pallet, rows divided by thermoformed interlayers keeping everything together, and a thermoformed lid on top
Twin sheet thermoformed packaging for batteries and engines can be smoothly integrated into the activity flow:
- They can be easily washed and sanitized
- They have a high stability level when stacked
- They are resistant to water and bad weather – maximum protection for products
- They can be sealed for improved safety
- They are very resistant to shocks and vibrations – increased safety in case of impact and on the road
- Recyclable at the end of their service life
- Customizable with a printed logo or labels for quick identification (including RFID tracking)
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Thermoformed pieces can be manufactured in a short time. This leads to an increased delivery rate and high productivity.
The cavities have a high degree of resistance against shocks, protecting the products during storage and transport.
The material sheets can be embossed to allow easy and safe identification of the product types for which the trays are intended. Handling indications are also embedded.
They are used in the automotive, pharmaceutical (thermoformed blisters) or food industries. They are suitable for storing and transporting small products, which cannot be packed in bulk, painted products or with sensitive surfaces, electronics with ESD properties, and sharp-edged or heavy objects. Metal compartments for very large presses can also be manufactured.
Thermoformed trays are recommendable for a good quality/price ratio, especially when delivering large volumes of parts.
These packages are a great way to reduce resource consumption and costs.
They have an ergonomic design, making them easy to handle by operators or automated equipment. Thermoformed packaging is usually nestable and space-efficient.
It does not require special storage conditions, and the workspace remains tidy.
They can be arranged in boxes or containers and remain fixed during storage and transport, ensuring product stability and optimal protection. They can be loaded directly on the pallet, and the products will be safe throughout handling.
Their low weight contributes to the general weight efficiency of the load.
Depending on the application, they can be returnable or disposable. One-way items can be produced from several materials depending on the desired application: ABS, HIPS, ESDPS, PVC, PET, PETG, RPET, PP, HDPE, PLA, and polyurethane.
One-way trays are made on automatic machines, and the film roll used to obtain them is usually less than 1 mm thick.
They are helpful in situations where their recovery is difficult or too expensive. Also valuable for projects with limited batches of items.
Even if they are non-returnable, the trays are durable. Their primary purpose is product protection, so the material used by us in production always fits the application’s requirements. They are recyclable, which ultimately eliminates waste concerns.
Reusable trays are made on semi-automatic machines, and the film roll used for their production is usually between 2 and 7 mm thick. They return with the packaging they occupied for transport.
The materials used ensure resistance to intensive use and the long service life of these packages.
The applications of thermoformed trays for the industry are:
- Blisters (accessories, locks, cables, etc.) – especially for one-way trips
- Packaging trays for transport and storage – small parts, bearings, injectors, sensors, various car components and more
