Specialized Packaging

Case Study

Handling Tote & Tray

We recently partnered with a defense industry client to develop a custom material handling solution tailored to their automated production process—engineered to meet the demanding needs of high-mix, high-precision part storage and transport.

The project called for a universal process tray that could seamlessly integrate into the client’s automated system—capable of holding multiple part diameters, maintaining consistent cavity locations for pick-and-place automation, and withstanding heavy stacking loads.

Case Study

ESD Safe Process Tray With Handles

We developed a custom process tray for a commercial electronics manufacturer, designed to move products safely and efficiently throughout the facility. To prevent finger entrapment when placed on low carts, the tray featured extended handles formed by bending a custom wire rim. The structure combined sonic-welded conductive fluted plastic (CFP) with the wire frame, providing exceptional durability and ergonomic handling.

The tray was engineered to fit precisely within its intended footprint, eliminating the need for anti-slip features. A Kleanstat Flex™ pad was added to accommodate smaller assemblies. While a Faraday cage was not required for this ESD-safe environment, a simple cover could have provided that functionality, if needed.

Case Study

Custom Thermoformed Trays

This solution employed conductive thermoformed trays designed to fit seamlessly with customer-owned injection molded totes, typically sized at either 9″ × 15″ or 15″ × 20″. Each tray featured multiple cavities to securely hold circuit boards, enabling efficient stacking and transport both within the facility and to external locations.

The new custom handling method eliminated the need for bags, foam inserts, multiple totes, and pizza-style boxes—streamlining logistics while reducing the risk of foreign object debris (FOD). For added protection, Kleanstat Flex™ pads were incorporated into the bottom of each tray, providing cushioning and ESD-safe contact surfaces.

To ensure audit readiness and compliance, each tray included an embossed ESD symbol, clearly indicating its electrostatic discharge safety rating.

Case Study

ESD Safe Thermoformed Insert For Industrial Totes

A custom thermoformed insert was designed to fit within an existing tote used in the manufacturer’s process, replacing standard dividers that failed to properly secure the product and had led to damage of high-value components.

The tailored tray securely held each unit in place, eliminated prior handling challenges and significantly enhanced protection. The thermoformed design provided improved physical and ESD protection, maximized tote capacity, and reduced the risk of FOD throughout the production process.

Case Study

Durastat Ribbed Adjustable Totes

An automotive electronics subcontractor required a universal packaging solution to transport four different PCBA designs between Mexico and the U.S.

This custom-engineered Durastat ribbed adjustable tote provided the answer—its CFP construction, card guide slots, and adjustable dividers securely accommodated all board sizes while preventing contact with sensitive components.

By implementing a single, adaptable tote design, the customer streamlined operations, simplified logistics, and reduced material handling variation across the program. This innovation delivered substantial cost savings upfront and even greater efficiencies over the life of the project.

Case Study

Conductive Fluted Plastic Tray With Custom Contours

This solution featured a precision-cut, multi-layer conductive fluted plastic insert engineered to securely house the customer’s circuit boards. It integrated seamlessly with their existing tray system and automated conveyor line, enhancing protection without requiring any system modifications.

While thermoformed trays were identified as the ideal long-term format, the custom insert provided an agile, immediately deployable alternative suited to current production volumes. It also replaced discontinued foam trays, eliminating FOD risks and ensuring reliable protection in high-precision handling environments.