Industrial Products and Packaging

Returnable Dunnage

T.O. Plastics excels at manufacturing highly engineered returnable packaging for specific applications. Backed by 30+ years of custom thermoforming experience, we can create a dunnage solution for a wide range of components.

Offering a maximum mold size of 55"W x 82"L x 20"D or 42"W x 80"L x 34"D, our returnable packaging is nest-able and durable. Because the dunnage we engineer is also stackable, each tote forms the lid for the container below, so you don’t have to source a separate lid.

We offer a wide variety of materials (styrene, ABS, polyethylene, polycarbonate, PET, PVC acrylics), including high-temperature options for applications requiring heat treating or finishing.

Our custom thermoforming capabilities include:

  • Expertise in anti-stat, static dissipative and conductive materials CNC milling;
  • Steel rule and heated forged dies 
  • 5-Axis CNC routing
  • Capable of reading surface conductivity of parts produced 
  • Burr-free trim with heated forged dies or line rule dies

T.O. Plastics also is a great choice for sustainable production. We use a closed-loop process, extruding thick-gauge material and thin-gauge roll stock, thermoforming that material and then reprocessing the scrap back into usable material.

Our innovative design team can engineer dunnage solutions for the most challenging applications. 


Contact us today for the returnable packaging you need.