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The packaging engineer inherited a tray program with a problem nobody wrote down: every time a bracket design changed, the hand-cut foam liners had to be recut by hand, and the tray itself was fine. Vacuum formed liners move that cost to a tool, which is why plants keep switching sheet by sheet.
Drop-in fit, no re-qualification of the box. The liner is formed against a model of the tray inner, so its edge ribs snap under the tray lip and stay put through a full shift of handling. The returnable box, the rack and the milk run schedule all stay untouched; only the liner changes.
Cavities that follow the pick logic. Cavity order can mirror the operator's sequence, left to right, heaviest first. Barcode positions stay visible between pockets, and family tooling keeps two related brackets in one tray so the picker never opens two boxes for one station.
Spec list:
VL 6004 liner: 600 x 400 mm footprint, 1.0 mm PP, 24 pockets, 45 g sheet weight.
VL 6004-HD: 600 x 400 mm, 1.5 mm HIPS, heavy bracket duty, 68 g sheet weight.
VL 4030 liner: 400 x 300 mm footprint, 0.8 mm PP, 12 pockets, 26 g sheet weight.
Material options: PP for wash lines, HIPS for dry zones, both regrind-tolerant.
Tool life: 200,000 forming cycles before cavity rework, typical.
From part model to production tool. Send the 3D part files or even just the tray drawing and sample parts. TOYOE lays out the cavities, cuts a vacuum form tool in aluminum, and delivers first articles in about two weeks. Design revisions cost a tool edit, not a new program.
If a tray family in your plant is still padded with cut foam, send one tray and one part; TOYOE will return a formed liner quote with a sheet gauge recommendation.
