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Thin blister trays are made for display shelves; production floors need something heavier. When a tray is picked up hundreds of times a day, stacked two-high on a trolley, and occasionally nudged by a forklift, wall thickness stops being a cost detail and becomes the service-life dial. These trays are thermoformed from heavy-gauge HDPE sheet, built for that kind of handling.
Wall thickness is the service-life dial
We start at 4 mm and go up to 8 mm depending on the load and the drop risk. Thick walls resist cracking at the radii, hold their stacking height for years, and can be reground and re-thermoformed at end of life instead of scrapped. The extra sheet cost is repaid many times over in trays that stay in service instead of rotating into the bin.
Why HDPE for the shop floor
HDPE absorbs impact without shattering, keeps its toughness well below freezing, and shrugs off the oils, coolants and mild cleaning agents found around machines. It does not stress-crack around inserts the way polystyrene does, and its low friction lets heavy parts slide into cavities without galling. For trays that live outdoors or in unheated annexes, HDPE is the default choice.
Standard heavy-gauge platforms
HG 1210: 1200 x 1000 mm footprint, 4-6 mm wall, cavity depth to 150 mm, payload 80 kg.
HG 865: 860 x 650 mm footprint, 4-5 mm wall, cavity depth to 110 mm, payload 40 kg.
HG 604: 600 x 400 mm footprint, 3-4 mm wall, cavity depth to 90 mm, payload 20 kg.
HG 432: 433 x 315 mm footprint, 3 mm wall, cavity depth to 70 mm, payload 10 kg.
Deep draws without thin corners
Deep cavities are where thin-gauge forming fails, so we plug-assist the deep pockets and pre-stretch the sheet to keep corner thickness close to nominal. Radii are sized for the material, ribs carry the stacking loads, and every design is proofed with a thickness map before the production tool is cut.
From drawing to running trays
Send a part drawing, a sample, or just the bin the tray has to fit. We return a cavity layout with a thickness map and a per-tray price at your annual volume; prototype trays come off a CNC-cut mould within two weeks, and production tooling follows once the fit trial is signed off.
Tell us the parts, the container, and how the trays are handled, and we will recommend a wall gauge that balances cost against the life you expect from the tray.
