The Initial Meeting

The Initial Meeting

The first step is to sit down with us and share your vision for your product. You’ll be partnered with a sales representative who will work with you throughout the process. We’ll establish the timeline for your project based on your needs. Some customers approach us up to two years before they intend to launch a product. But when speed-to-market is crucial, you can expect the lead times referenced here.

The Sketch

The Sketch

Within the first three-to-five days, our team of 13 full-time design engineers and graphic designers will turn your idea into a sketch of a package that is manufacturable, and submit it to you for approval. If you approve the sketch, we’ll provide a quote.

Prototyping

Prototyping

Within two-to-10 days after that, we’ll create the first prototype to submit to you for approval. We can form parts from aluminum, REN, or 3D printed molds, depending on the complexity of the design. Most prototypes need to be tweaked and perfected, so we factor in time for multiple iterations. We will work with you to test the prototype in your production line, evaluate the workflow, and collaborate to find the most functional design. We can also coordinate our work directly with suppliers of labels, printers or boxes to make sure your overall packaging solution works.

High-Volume Production

High-Volume Production

Once you approve the prototype, our in-house team of 33 full-time mold makers will begin building the tool to create your product. They will test and refine the tool and then submit samples of production parts to your team. After you give approval on the production part, we will begin full-scale production.

The Thermoforming Process

The Thermoforming Process

Thermoforming is not a set-it-and-forget-it process. The 54 thermoforming lines across our six locations require careful monitoring and frequent adjustments for all of the variables in play, like the type of material, the thickness of the packaging, and the temperature of the mold after running for hours. With an average tenure of 18.5 years, our thermoforming technicians have honed the skills required to manufacture flawless, innovative packaging.

The Final Product

The Final Product

The time from prototype approval to order completion ranges from two to 12 weeks, depending on complexity of the piece. No matter the scope or scale of your project, the finished product will be a beautiful, high-quality thermoformed packaging solution.

Ongoing Support

Ongoing Support

We don’t consider the job done until our packaging is smoothly integrated into your production line. If you encounter any issues, we’ll address them within 24 hours. If the part is not behaving properly and needs to be revised, our team can adjust the specifications within a few days to minimize downtime in your system.