Custom Thermoformed Plastic Trays
FormTight designs and manufactures custom thermoformed trays engineered for product protection, presentation, and production efficiency. From medical device trays used in surgical settings to food packaging found in local supermarkets, we handle every stage of manufacturing for both thin- and thick-gauge thermoformed trays at our Denver, Colorado, facility.
Thin Gauge Tray Applications
Thin gauge thermoforming is standard for food, retail, and medical packaging applications.
Food Packaging Trays:
- Produce trays for fresh display and protection
- Trays for baked goods, muffin, and donut formats
- Confection and chocolate trays
- Frozen meal trays
- Snack packs
- Single use meal items
PET and HIPS are the most common material selections for food tray applications. FormTight has years of experience in the food industry and completes an annual packaging materials audit through Mérieux NutriSciences to support food safety compliance requirements.
Retail Packaging Trays:
- Insert trays designed to hold and present a product at point of purchase
- Display trays for shelf-ready packaging formats
- Multi-product organizational trays
- Protective shipping insert trays
Medical Packaging Trays:
- Sterilization trays
- Procedure and surgical kit trays
- Catheter holders
- Device component organizers for single-use and reusable medical packaging
Thick Gauge Tray Applications
Thick gauge thermoforming is used where structural integrity, wall thickness, and dimensional repeatability are the primary requirements. FormTight's equipment handles sheets up to 53" x 101", with all trimming handled in-house via 5-axis CNC.
Industrial Dunnage Trays
- Designed around the specific geometry of the parts they carry, whether a single deep-draw cavity or a multi-part configuration is required
- Common materials include ABS, HDPE, and HIPS, with selection driven by load requirements
- Available in returnable or single-use configurations, depending on application requirements
OEM Parts and Large-Format Trays
- OEM component trays formed to specific part geometry
- Equipment housings for commercial and industrial applications
- Large-dimension structural components requiring consistent geometry across production runs
Hydroponic Trays
- Custom dimensions and channel configurations available
- Thermoforming can produce consistent geometry in larger formats suited to hydroponic grow tray requirements
Materials
FormTight works with PET, PETG, HIPS, ABS, HDPE, PP, PVC, and PC across thin and thick gauge tray projects. Material selection is determined during project scoping based on application, environment, regulatory requirements, and performance expectations. Need help selecting a material? Our team can recommend options based on your specific product requirements.
Start Your Custom Thermoformed Tray Project
Whether you need food packaging trays, medical device trays, or heavy duty industrial trays, FormTight can help develop a thermoformed solution built for specifically for your need.
PETG - Custom Medical Device Tray
Thin Clear Lid and Tray
Thin Black Clear & White Trays
Thin Tray and Lid