Custom Heavy Gauge Returnable Dunnage Trays
Blue Ridge Thermoforming (BRT USA) in Greenville, SC makes custom heavy-gauge thermoformed returnable dunnage trays for automotive suppliers and OEMs.
Blue Ridge Thermoforming manufactures custom heavy gauge thermoformed automotive packaging, returnable dunnage, and component trays that deliver superior protection, efficient material handling, and multi-year durability for automotive suppliers and OEMs. At Blue Ridge Thermoforming, we specialize in durable, custom-fit automotive packaging designed for protection, efficiency, and sustainability. Our heavy gauge thermoformed solutions eliminate waste through reusable designs while ensuring components arrive undamaged and ready for assembly. This is part of our heavy gauge thermoforming work in Greenville, SC.
Request a QuoteWhat returnable dunnage trays cover
Returnable dunnage is reusable packaging designed to protect and transport automotive components between suppliers and assembly plants. It eliminates single-use packaging waste, reduces costs over time, and ensures consistent part protection throughout the supply chain.
Our heavy gauge thermoforming process supports returnable dunnage and component trays, automotive parts packaging and protection, material handling systems, and custom-fit packaging for complex geometries. Whether you are shipping components across the country or across the plant floor, the packaging is designed to protect parts and streamline operations.
- Returnable dunnage and component trays
- Automotive parts packaging and protection
- Custom-fit packaging for complex geometries
- Stack or nest designs for efficient storage and transport
- Custom cavity configurations for complex part geometries
- Structural reinforcement ribs for load-bearing capacity
- Color coding for different component types
Materials and a published automotive case study
Materials commonly used for this automotive packaging include HDPE for impact resistance and durability, ABS for surface quality and strength, polypropylene for chemical resistance and flexibility, and HMWPE for extreme impact resistance. Custom blends are available for specific requirements.
A published case study of a Tier 1 automotive supplier describes a custom thermoformed tray, formed from 100% post-industrial recycled HDPE and durable for 20+ reuse cycles. That program eliminated over 24,000 lbs of expendable packaging waste in the first year and saved approximately $180,000 annually on packaging and damage-related costs.
The case study tray was engineered from recycled HDPE so it could cradle each part, with contours that address vibration and abrasion during shipping. The tray is chemical and moisture resistant and fully recyclable at end of life.
Why automotive teams use this process
For automotive packaging, heavy gauge thermoforming is a cost-effective alternative to injection molding, with lower cost per part, custom part geometry designed to fit the component, and durable, reusable trays with multi-year service life in demanding environments.
Blue Ridge Thermoforming supports the packaging development path from design collaboration and part geometry analysis through in-house tooling, material selection, heavy gauge thermoforming and pressure forming, and precision 5-axis CNC trimming for assembly-ready parts. Work is done under ISO 9001:2015 certified quality processes, with in-house design, tooling, and 5-axis CNC trimming, in Greenville, SC.
Related pages
This use case is part of Automotive Packaging. See also Automotive and Reusable automotive packaging case study.
FAQs
What is returnable dunnage and why is it important for automotive manufacturing?
Returnable dunnage is reusable packaging designed to protect and transport automotive components between suppliers and assembly plants. It eliminates single-use packaging waste, reduces costs over time, and ensures consistent part protection throughout the supply chain.
Can you design packaging for multiple part variations?
Yes. We can create modular cavity designs or family tools that accommodate multiple part variations while maintaining protection and efficiency.
How long do automotive packaging trays typically last?
Our heavy gauge thermoformed automotive packaging is designed for multi-year service life with proper handling. Depending on material selection and usage patterns, trays can withstand hundreds to thousands of cycles.
Request a quote
Contact Blue Ridge Thermoforming to discuss your thermoforming project.