Dunnage Trays
Engineered Trays Built for Protection
Custom Thermoformed Trays | Dunnage, WIP, Handling, Medical, Insert & Assembly Trays
Averra Packaging designs and manufactures custom thermoformed trays for a wide range of industries, including automotive, industrial, electronics, and medical device manufacturing. With deep expertise in thermoforming and precision engineering, Averra delivers end-to-end tray development, from part evaluation and tray design to tooling, forming, and quality assurance.
Our team specializes in creating trays that protect components, improve workflow efficiency, and integrate seamlessly with both manual and automated handling systems.
Thermoformed Tray Solutions
Industrial Dunnage & WIP / Assembly Trays
Designed to interface with manual handling, conveyors, or robotic systems.
· Precision cavities ensure consistent part orientation
· Locating features support automation and assembly accuracy
· Reusable, impact-resistant designs minimize part damage and downtime
Ideal for automotive components, machined parts, electronic assemblies, and complex multi-component kits.
Custom Thermoformed Trays
For sterile or clean manufacturing environments, Averra supplies class 8 custom medical trays engineered for device integrity, sterilization and regulatory requirements.
· A variety of material options are available based on the method of sterilization being used.
· Designs optimized for sterilization pallet configurations, procedural workflows and kitting
· Ideal for device protection, surgical kits, and assembly processes
Learn more about Averra's medical device packaging tray capabilities.
Retail & Customer Insert Trays
Custom insert trays enhance product presentation and protection inside retail and e-commerce packaging. Perfect for electronics, personal care, wellness, and specialty consumer goods.
Key Features
Custom-Engineered
Each tray is tailored to your part’s geometry and manufacturing process, providing precise fit, protection, and orientation.
Material Optimization
Our Engineers ensure that the polymer selected for the prototyping and production of your tray is based on the specific requirements of your project.
Cost-Efficient Tooling
Thermoforming offers lower tooling costs than injection molding, making it a great choice regardless of production volumes.
Lightweight, Durable Construction
Strong enough for repeated handling while minimizing load weight & shipping expenses.
Available Materials
Averra can manufacture trays from a variety of polymers, including but not limited to: rPET, PET, rPETG, PETG, rHIPS, HIPS, PVC, rHDPE, HDPE & PP. We also offer materials with a range of ESD & Anti-Stat properties.
Integrated Design, Tooling & Manufacturing
Averra offers a cohesive, in-house process that ensures speed, precision, and consistency.
Custom Tray Design & Engineering
Our engineering team develops trays optimized for performance, manufacturability, and automation compatibility. We use advanced CAD modeling to ensure accurate part nesting, stackability, and ergonomic handling.
Tooling Development
Prototype and production tooling are built with tight tolerances to ensure consistent forming and repeatability. Our tooling capabilities allow for rapid iterations and controlled quality from concept to full production.
Precision Thermoforming
Averra thermoforms trays with repeatable accuracy for:
· Multi-cavity components
· Complex geometries
· Robotic pick-and-place compatibility
Class 8 Cleanroom Production Capabilities
Averra Packaging recently doubled our class 8 cleanroom manufacturing capabilities. Click here to learn more.Quality Assurance for Thermoformed Trays
Quality is integrated into every phase of Averra’s process. Averra Packaging is an ISO 9001 & ISO 13485 certified manufacturer of custom thermoformed packaging. Our quality systems support tight dimensional control and consistency across production runs.
Process Controls & Inspection
· First Article Inspection
· Dimensional verification of key features
· In-process quality checks
· Statistical process monitoring for repeatability
Why Work with Averra for Custom Thermoformed Trays?
· Application-specific tray design tailored to your manufacturing flow
· Integrated tooling and production for faster lead times and better control
· Expertise across industrial, medical, and high-precision applications
· Flexible, collaborative engineering support
· Reliable, repeatable quality for demanding production environments
How can we help you?
We know that rapid change and evolving regulations are standard in healthcare. But our talented, responsive team members are here to troubleshoot your unique packaging and supply chain challenges at every turn. Contact us today to see what we can do for you.
