Dunnage & returnable packaging
Thermoformed dunnage & returnable packaging
In an OEM supply chain, parts move thousands of times in reusable dunnage — and every scuff, rattle or crush is a rejected component. Indu Thermoformers forms part-specific dunnage trays, tote inserts and returnable handling packaging in durable HDPE, ABS and PP, with cavities cut to protect exactly the parts you ship.
Dunnage designed around the part, not the box
A good dunnage tray holds each component in its own cavity, stacks safely, and drops into your standard tote or rack. We form tough HDPE and impact-modified ABS for scuff- and impact-resistance across thousands of trips, and ESD grades where electronics need static protection in transit. Cavities, ribs and stacking lugs are formed in so parts do not touch, nests hold under vibration, and empties collapse or stack for the return leg.
Big parts, fast tools, in-house loop
With thin- and thick-gauge lines — including the largest thermoforming bed in India — we form dunnage for everything from small connectors to full body panels. Soft tooling is cut in-house in weeks and cheap to revise as parts evolve, and skeletal scrap is reground and re-extruded in-house, keeping returnable-packaging programmes cost-effective and lower-footprint.
Dunnage & handling we thermoform
Materials & datasheets
Why Indu for dunnage & returnable packaging
In-house sheet extrusion
We extrude the sheet we form — grade, colour and thickness controlled from the pellet, with no outside vendor in the loop.
Largest bed in India
Thin- and thick-gauge lines, including the largest thermoforming bed in the country for oversized parts.
Tooling in 2–4 weeks
Moulds and trim fixtures designed and cut in-house on 5-axis CNC — fast, and cheap to revise.
ISO 9001 & full docs
8-gate inspection with COA, MTC, FAIR and PPAP-level documentation on request.
Frequently asked questions
What is thermoformed dunnage?
Dunnage is reusable protective packaging with part-specific cavities that hold components during handling and transport. Thermoforming makes it cost-effectively, with cavities and stacking features formed straight into durable sheet.
What materials are dunnage trays made from?
Usually tough HDPE, impact-modified ABS or fatigue-resistant PP for thousands of reuse trips. ESD grades are used where electronics need static protection in transit.
Can you match our tote or rack system?
Yes — trays are designed to nest into your standard totes, bins or racks, with cavities, stacking lugs and collapse/return features to suit your loop.
How large a part can you make dunnage for?
From small connectors to full automotive body panels — we run the largest thermoforming bed in India for oversized carriers and layer trays.
Let’s build it
Need returnable dunnage?
Send the part you need to protect — a drawing, STEP file or sample — and we reply with cavity design, material and a costed quote, usually within 24 hours.
ISO 9001:2015 certified · Most quotes back within 24 hours