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Thermoformed Products

Finding the right product packaging can be a complex and frustrating process – with so many standard options on the market and millions of unique items that require a specialized packaging design. That’s where Great River Plastics comes in as your guide. We’ve been helping brands like you to overcome the challenges of packaging for 25 years. Our expertise in thermoformed products allows us to custom-create the perfect packaging solutions for your commodities.

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Our Thermoformed Solutions

Clamshell Packaging

Clamshell packaging manufactured by Great River Plastics, is custom thermoformed to meet your exact specifications. Our plastic clamshell packages for retail products include allowance for insert cards with product information and graphics. Our sealing capabilities allow the clamshell containers to be either reclosable or completely sealed.
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Clamshell Packaging

Plastic tray packaging

Clamshell packaging manufactured by Great River Plastics, is custom thermoformed to meet your exact specifications. Our plastic clamshell packages for retail products include allowance for insert cards with product information and graphics. Our sealing capabilities allow the clamshell containers to be either reclosable or completely sealed.
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Plastic tray packaging

Material Handling Trays

Clamshell packaging manufactured by Great River Plastics, is custom thermoformed to meet your exact specifications. Our plastic clamshell packages for retail products include allowance for insert cards with product information and graphics. Our sealing capabilities allow the clamshell containers to be either reclosable or completely sealed.
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Material Handling Trays

Plastic inserts

Clamshell packaging manufactured by Great River Plastics, is custom thermoformed to meet your exact specifications. Our plastic clamshell packages for retail products include allowance for insert cards with product information and graphics. Our sealing capabilities allow the clamshell containers to be either reclosable or completely sealed.
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Plastic inserts

Specialty Products

Clamshell packaging manufactured by Great River Plastics, is custom thermoformed to meet your exact specifications. Our plastic clamshell packages for retail products include allowance for insert cards with product information and graphics. Our sealing capabilities allow the clamshell containers to be either reclosable or completely sealed.
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Specialty Products

Packaging Made For You

You no longer have to settle for generic, one-size-fits-all packaging. With our sophisticated thermoforming capabilities, we’ll create packaging that catches the eye, is made to last, and is perfectly tailored to protect and showcase your specific product so that it shines amongst competitors. Let us lead the way with flexible packaging options that’ll brighten your products on the shelf and delight your customers.

Our Capabilities

  • Sheet sizes up to 35″ x 39″
  • Vacuum and Pressure Forming
  • In-House Pattern and Mold Design
  • Tooling and Prototyping
  • Large Production Runs
  • Material Gauge .007 to 0.060
  • Forming of PVC, HIPS, PETG, PETE and HDPE
  • Custom Colors, Products, and Assembly
  • Fulfillment Services Available

Industries We Serve

Retail

Electronics

Food

Automotive

Medical

Cosmetics

Custom

Whichever niche your products fall into – carry-out food, dental equipment, automotive – you name it – we’ll craft packaging that will not only ensure protection from damage and theft, but also promote brand visibility and sales. Browse our thermoformed packaging products today to find the exact solution you need to guarantee safe transportation and customer satisfaction. Call today at 800-914-8994 or 608-723-5110.

Contact Us

Please contact Great River Plastics, 800-914-8994 or 608-723-5110, for more information about any of our custom thermoformed plastic material handling trays, clamshell packages, or plastic packaging products. Large quantity orders are custom designed and made to meet your specific requirements.

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    Frequently Asked Questions

    What thermoformed plastic products does Great River Plastics manufacture?

    Great River Plastics manufactures a multitude of custom thermoformed products, among which are plastic trays, material handling trays, clamshell packaging, plastic inserts, specialty packaging, and custom thermoformed solutions tailor-made to each customer’s products and objectives.

    Can you manufacture custom thermoformed plastic trays?

    Yes. We can design thermoformed plastic trays around your product’s exact dimensions, handling requirements, and shipping needs. Custom trays help strengthen product protection, improve organization, and support more efficient manufacturing workflows.

    What industries use thermoformed plastic trays?

    Our thermoformed products support industries spanning automotive, electronics, food processing, medical, retail, cosmetics, and industrial manufacturing. We provide customized design packaging solutions that align with each industry’s distinct handling and protection requirements.

    What materials are available for thermoformed packaging?

    We manufacture thermoformed products using materials such as PVC, PETG, PETE, HIPS, and HDPE. Material selection hinges on your product, durability and appearance objectives, and intended application.

    What is the difference between a material handling tray and a packaging tray?

    Material handling trays are designed to safely transport and organize components throughout manufacturing and assembly processes; packaging trays are typically intended for retail presentation, shipping, or product storage.

    Can thermoformed trays be designed for automation?

    Yes. Our custom trays can be engineered for robotic pick-and-place systems, automated assembly lines, stacking, nesting, and other manufacturing automation processes to improve operational efficiency.

    Do you provide design and prototyping services?

    Yes. Great River Plastics offers in-house design, tooling, mold development, and prototyping services so as to ensure your custom thermoformed product meets performance and production requirements before full-scale manufacturing occurs.

    What production volumes can you accommodate?

    We specialize in high-volume production and large manufacturing runs, and our production capabilities support ongoing commercial and industrial packaging needs.

    Are your thermoformed plastic products made in the USA?

    Yes. All of our thermoformed plastic trays and packaging products are manufactured in Lancaster, Wisconsin, where we abide by strict quality standards, provide dependable lead times, and prioritize responsive customer support.

    Can you create custom clamshell packaging?

    Absolutely. We manufacture custom thermoformed clamshell packaging to fit your product precisely; options include reclosable clamshells, fully sealed packaging, and designs that accommodate printed insert cards for retail display.

    Do you offer environmentally friendly packaging options?

    Yes. We offer recyclable material options and work with customers to develop packaging solutions that support sustainability initiatives with the same high level of durability and performance.

    What size thermoformed products can you manufacture?

    Our manufacturing capabilities include sheet sizes up to 35″ × 39″ and material gauges ranging from .007″ to .060″. We can produce everything from lightweight retail packaging to durable industrial trays.

    Can plastic trays protect delicate or precision parts?

    Yes. Custom thermoformed trays are inherently designed to securely hold parts in place during transportation and handling, limiting movement, preventing damage, and improving organization for sensitive or precision components.

    What are plastic insert trays used for?

    Plastic insert trays are utilized to organize, separate, cushion, and protect products inside boxes, cartons, and display packaging. These trays serve critical packaging functions for electronics, medical devices, consumer goods, and industrial components.

    How do I get started on a custom thermoformed packaging project?

    Simply contact our team with your product specifications, application requirements, expected production volume, and packaging goals. We’ll work with you through consultation, design, prototyping, tooling, and full-scale production to develop a solution that best fits your needs.