Plastic parts where your product fits perfectly
We design and manufacture custom thermoformed parts that embrace your product and immobilize it inside the box. Goodbye to die-cut cardboard, foam, fillers.
We replace: EPS • expanded polystyrene • PUR • foams • die-cut cardboard • manual fillers.
With: a single thermoplastic part designed for your product.
From filler to structure
Conventional packaging is generic – the part goes into a box and the void is filled. Our proposal is the opposite: a part designed for your product that immobilizes it by geometry, not by filler.
THE CONVENTIONAL
EPS, foams, die-cut cardboard, fillers.
Protection depends on how much material you add around the product. It is a solution by approximation, not by design.
- × Does not secure the product: allows movement during transport
- × Variability - each box is filled differently
- × Single-use material, fragile, degrades quickly
- × Generates bulky waste that is difficult to manage
- × Recurring cost: each shipment needs new material
- × Non-recyclable or difficult to recycle
THE CTE
A thermoformed part customized to your product.
We design in CAD a part whose geometry is the exact inverse of the product. It embraces it, secures it, protects it. No play.
- × Complete immobilization: zero movement inside the box
- × Repeatability: each part is identical to the next
- × Reusable: withstands many cycles without losing properties
- × A single lightweight part that replaces several elements
- × Recyclable material, kept in circuit if the customer so wishes
- × Reduces cost per cycle and eliminates waste per shipment
One refrigerator door, zero movements in transport
Thermoformed trays solve four concrete challenges in any supply chain. They work both inside your plant and between your company and your suppliers or customers.
The challenge
Large, fragile doors with play inside the box
The customer needed a system to package refrigerator doors that would keep them fixed and protected inside the box during transport. The doors, due to their size and surface fragility, are especially sensitive to impacts, scratches and displacement. They were protected with EPS (expanded polystyrene) parts that provided basic cushioning, but did not guarantee precise fixation: the door moved during transport, causing scratches and surface damage. In addition, EPS is single-use, fragile, generates bulky waste and degrades easily after few uses.
The CTE solution
A thermoformed part designed to the exact geometry of the door
CTE developed a thermoformed part tailored to the door, which fixes it precisely inside the box and protects it throughout the transport cycle. The part adapts perfectly to the door geometry, eliminating play and ensuring complete immobilization.
Advantages delivered
Five concrete improvements versus the previous EPS solution.
01
Custom fixation
The part embraces the door and immobilizes it, eliminating movements and impacts.
02
Superior protection
Versus EPS, thanks to the exact fit to the product geometry.
03
Reusable
Returnable solution, reducing cost per cycle and waste generation.
04
Lightweight part
Does not significantly increase packaging weight.
05
Recyclable
Resistant material that maintains its properties after multiple uses.
For products that generic packaging does not protect well
Custom industrial packaging solves the cases where the standard solution - box + filler - fails. Products with complex geometry, fragile, bulky or high-value that need more than a bit of foam around them.
Home appliances
Large-format doors, panels, housings and modules that require impeccable surface protection during transport.
Automotive
Large or fragile components - panels, headlights, bumpers, preassembled assemblies - that travel between Tier supplier and OEM plant.
Industrial machinery
Heavy mechanical components, sensitive measuring equipment, motors and electromechanical assemblies that need absolute immobilization.
Fragile or high-value products
Medical equipment, precision instrumentation, delicate electronic products, unique or high-cost parts that cannot afford a failure.
From the product 3D to the part, in three steps
01
Analysis and design
We study the product geometry, critical points (fragile zones, edges, aesthetic surfaces) and the logistics loop. We model the part in CAD with the exact fit and reinforcements where needed.
02
Prototype and testing
Series thermoforming with material extruded on our own lines. If the solution is returnable, we also manage the return cycle and batch traceability.
03
Series production
Series thermoforming with material extruded on our own lines. If the solution is returnable, we also manage the return cycle and batch traceability.