Vacuum Formed Trays & Inserts

Overview

Our vacuum formed trays and inserts are custom moulded plastic components used to hold, protect, and display products during shipping, storage and retail presentation. They’re created by heating a plastic sheet and vacuum forming it over a mould to shape it precisely to the desired dimensions. We use a number of different materials, such as RPET, which is the most commonly used. This material has a high recycled content and is completely recyclable; it can simply be placed in a household kerbside recycling bin. Other materials, such as HIPS, are available and can be formulated to a colour of your choice. Key Benefits of our Vacuum Formed Trays and Inserts:

 

Product Protection
  • Secure fit: Custom cavities hold products in place, reducing movement and the risk of  damage during transport.
  • Shock absorption: Helps cushion items from vibration and impact.
Bespoke Designs
  • Designed to fit unique product shapes and sizes, improving presentation and functionality.
  • Can include features like stacking lugs, finger holes, or anti-static materials.
Improved Organization 
  • Keeps products organised and separated, particularly useful for kits or multi-component  items.
  • Easy to count and inspect parts in industrial or medical applications.
Material Efficiency
  • Uses less material than full box packaging while still providing structure.
  • Available in recyclable material (e.g. PET & RPET).
Aesthetic and Retail Display Value
  • Clear or coloured options for visibility and branding.
  • Ideal for shelf-ready retail packaging adds premium feel and makes unpacking easier for  consumers.
Reusability
  • Durable trays can be used multiple times, particularly in manufacturing or closed loop logistics systems.
Popular applications
Electronics
Holding delicate components, anti-static inserts
Medical/Pharma
Sterile product handling, surgical kits
Automotive
Part separation and shipping trays
Food & Beverage
Bakery trays, meat packaging, snack trays
Retail/Consumer
Cosmetic sets, gift packs, toys, and tools