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Custom Thermoformed Dunnage and Industrial Trays

Heavy Gauge Thermoforming: Reusable Pallet Tote

CJK is experienced in working with you to develop the most effective – and cost effective – industrial packaging solution for your products.

Whether you need dunnage, pallet liners or heavy industrial packaging, we have the expertise, in-house tooling, and facility to produce large and short orders.

Heavy Gauge Thermoforming CAPABILITIES

Packaging: Dunnage, Pallet liners, Large Industrial Trays

Even large components need well designed protective packaging with the same detail to placement and orientation as do smaller components. Whether it be an FDA or Industrial application, we design all tooling in-house, and can form sheet stock in thicknesses from .060” to .625” and perimeter dimensions up to 4’ x 6’.


  • Durable, strong, and functional
  • Temperature stability
  • Dimensional stability
  • Long service life
  • Heavyweight
  • Limited design ability
  • Costly
  • Subject to corrosion
  • Subject to unwanted chemical reactions
  • Expensive to add specialized features


  • Durable, strong, and functional
  • Temperature stability
  • Dimensional stability
  • Long service life
  • Lightweight
  • Increased opportunities for design
  • Inexpensive
  • Corrosion-resistant
  • Chemical-resistant
  • Cost-effective to incorporate specialized features

Forming Capabilities

Heavy Gauge Sheet Thermoforming and Pressure Forming:

  • Forming material thickness .040” – .625”
  • Using materials virgin and recycled PVC, PETE, HIPS, HDPE, PP, ABS, PC, Kydex [Conductive, Static Dissipative, UL and FR Grades, plus other engineering grades]

We’ve manufactured custom OEM products ranging from heavy-duty engine covers, to lawnmower tops, to airflow vents, to medical equipment coverings and containment systems for the U.S. Department of Defense. Heavy gauge polymer products will survive harsh environments and give long maintenance free service life.

Thermoforming vs. Injection Molding

Custom Packaging for Food and Retail
  • Significantly faster tool lead times for speed to market
  • Significantly lower tool cost / capital investments
  • Cost-effective process provides greater opportunity for product redesigns

We're a one-stop-shop for our OEM customers

custom tool
Custom tool design and manufacturing
complete trimming
Complete trimming with 3- and 5-axis CNC router capabilities, die-cutting, and punch and drill operations
general assembly
General assembly
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Adhesive bonding
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Hot stamp, painting, screen printing, labeling, and other decorating options
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Bosses, threaded inserts, and other fastener systems
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Logistic services

The CJK Process

for Custom OEM Components

CJK can manage the project from start to finish.

  1. 1.
    Evaluate customer-supplied design
  2. 2.
    CJK creates 3D solid model for initial approval
  3. 3.
    CJK machines all molds and production fixtures in-house
  4. 4.
    Prototype or 1st article is evaluated and approved
  5. 5.
    Full production of final product begins

Key Features and Benefits

When we work with our clients in the development of OEM enclosures, guards, covers, facias, and panels, our design engineering process focuses on the following key features and benefits.

  • Low-cost product and tooling
  • Customized design details to handle customer product and process functional criteria. Considerations for positioning, retention, and protection of product as applicable
  • Distribution requirements
  • Outdoor environmental considerations for design and appropriate material selection
  • Excellent aesthetics
  • Ergonomic considerations for:
    • Clients’ product assembly process –manual or automatic. Ease of assembly for increased efficiency and reduced cost
    • Consumer appeal and ease of use to enhance customer satisfaction, brand preference and repeat purchases of the product
  • Text/engraving or decorating requirements for corporate logos, part numbers, desired text, resin ID codes, etc. for identification and branding


Materials typically used for OEM enclosures, guards, covers, facias, and panels include: PETE, HDPE, PP, HIPS, PVC, PETG, ABS, Kydex, Polycarbonate and others. Recycled, virgin, blends, FDA grade, and medical grades are also available.

Clear, black, white and custom colors are available, along with various textures such as smooth, matte, gloss, hair cell, etc. View our complete list of commonly used materials.


Sustainability and eco-consciousness are top-of-mind at CJK. Every process and product we create, we do so with the environment in mind.

Unlike paper, which can only be recycled 2-3 times before it loses fiber strength, polymer packaging can be ground, reintroduced, and reformed indefinitely.

We use recycled grade polymer materials in well over 90% of our FDA and retail packaging products. all processing waste is sorted, ground, and returned to polymer processors that reintroduce 100% back into reusable products.

We use recycled grade polymer materials in well over 90% of our FDA and retail packaging products.

All of our products and packaging:

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Are beneficial, safe, and healthy for individuals and communities throughout its life cycle.
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Meet market criteria for performance and cost.
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Are sourced, manufactured, transported, and recycled using renewable energy.
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Maximize the use of renewable or recycled source materials.
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Are manufactured using clean production technologies and best practices.
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Are made from materials healthy in all probable end-of-life scenarios.
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Are physically designed to optimize materials and energy.
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Are effectively recovered and utilized in biological and/or industrial cradle to cradle cycles.

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