Need more information?

or call 1 (800) 383-7092


What are average lead times?
Do you have full service packaging design services?
Do you have a clean room?
Are you ISO Certified?
Do you have minimum quantities?
What packaging do you have in stock?
Do you design packaging?
What kind of software do you use?
What is the process to develop a new package?
How much will my tooling cost?
Can you supply high impact packaging?
What can be done to make our packaging come apart easier?
Will your packaging withstand heat?
What are the different sealing techniques available?
Is your packaging recyclable?
Do you ship worldwide?
What is Custom Thermoforming?

FAQ Shortcuts
General Questions
Product Descriptions
Brookdale Plastics Tools
Materials Descriptions
Manufacturing Terms


What are average lead times?
Our sales and engineering team will work closely with you to understand your time constraints and do everything possible to meet or exceed your expectations.

Do you have full service packaging design services?
We offer complete, end-to-end packaging solutions. An element of that offering is our award winning design services as a part of your total project.

Do you have a clean room?
Yes. Our Class 100,000 Clean Rooms are certified to meet or exceed the stated class conditions in accordance with Federal Standard 209E and ISO 14644 Part I. The temperature and humidity are highly regulated and the air repeatedly filtered in order to protect packaging from contamination.

Are you ISO Certified?
Yes. Brookdale Plastics is Certified ISO9001:2008 through Orion Register, Incorporated – certificate ID A0001348-1

Do you have minimum quantities?
We don’t have a set minimum. It really depends upon the requirements of the packaging design and materials used. However, keep in mind that the larger the order, the more we can save you in per-part costs.

Your best option is to contact us for an estimate on your project. Simply fill out our Quick Response Form or call us at 1(800) 383-7092 to get the specific information you need.

What packaging do you have in stock?
Because we are a custom packaging thermoformer, we do not have in-stock packages; we customize the packaging solution to each client’s exact needs. We are very flexible and innovative in our packaging and often able to meet very tight packaging deadlines; use our Quick Response Form to get us started on a solution for you, or browse our Packaging Samples to see some of our past customized packages.

Do you design packaging?
Yes, we do. Our design team specializes in three custom thermoformed packaging design markets:

We also have extensive experience thermoforming plastics with these properties:

  • Conductive
  • Anti-static
  • Static dissipative

These are some of your options in packaging styles:

  • Blister packs
  • Clamshells
  • Tri-folds
  • Trays
  • Or something totally new

To find the perfect custom thermoformed packaging solution for your product, contact us by filling out our Quick Response Form or call us at 1(800) 383-7092.

What kind of software do you use?
We use a variety of software to analyze client’s needs and solve their packaging problems. Please see the Brookdale Plastics Tools section for detailed descriptions.

What is the process to develop a new package?
We begin with an assessment of your packaging needs through meetings and analysis. From there, using our 3D design software, our engineers create a packaging concept for you.

Once this design is approved, we move to developing prototype tooling which we use to create prototype packaging. The prototype packaging is then presented for your approval. When the packaging meets your final approval, we create the production tooling and, when you are ready, begin creating your packaging in our production facility.

How much will my tooling cost?
Tooling costs vary dramatically; it depends upon the complexity of the packaging design and material requirements to meet your packaging needs. Find more information on our Tooling and Prototyping page or simply fill out our Quick Response Form and we’ll start getting the information we’ll need to get you an estimate.

Can you supply high impact packaging?
Yes, we can. Many custom thermoformable plastics have an amazing capacity to resist impact under difficult conditions. The design of the packaging itself can also contribute to the protection of your product.

What can be done to make our packaging come apart easier?
Our design team will design packaging with de-nesting features that allows easy separation of parts. Further, there are many material options that have surface or internal additives that allow parts to be easily separated.

Will your packaging withstand heat?
Yes, we have several options available depending upon the heat range required and your other packaging requirements. The best way to find the perfect solution for your high-heat packaging needs is to contact us.

What are the different sealing techniques available?
You have many options for sealability. We can create blister packs that are heat or adhesive sealed, clamshells that are RF sealed, thermoformed trays with clear or Tyvek sealed lids, snap ring seals... the list of packaging types and sealing goes on and on. Simply contact Brookdale Plastics to learn about the best sealing option for your plastic packaging requirements.

Is your packaging recyclable?
Most of our packaging options are recyclable. It often depends on how stringent your product needs are as to whether a recyclable or recycled plastic can be used. Find additional information on our Sustainability and Recycling page, or simply fill out our Quick Response Form to find out how recycling fits in with your custom thermoformed packaging needs.

Do you ship worldwide?
Yes, Brookdale Plastics has the capability to ship packaging worldwide. However; some countries, such as the EU, do have some packaging materials restrictions so it’s best to send us your specific shipping question(s) and packaging needs with our Quick Response Form and we will get back to you with the specifics you need.

What is Custom Thermoforming?
Custom thermoforming is the process of heating a plastic sheet and using vacuum to shape it over a custom designed mold. The parts are then cut, trimmed and assembled into packaging designed specifically for your product.

Brookdale Plastics custom thermoforms a wide variety of materials including PVC, HIPS, PETG, RPET, HDPE, and PP in material thicknesses ranging from .0075" to .060". And we manufacture part sizes up to 37" x 57" with heights of up to 6".

Contact Brookdale Plastics now; fill out our Quick Response Form or call us at 1(800) 383-7092.

Product Descriptions Back to top


Blister: A blister is a basic, cost effective custom thermoformed packaging solution that protects your product behind a clear plastic “blister” sealed to an informational card. Also called a blister pack or blisterpak.

Clamshell: A clamshell or clam shell is a custom thermoformed package that allows both front and back viewing of the product. Usually, it is flat on the back with a “blister shape” on the front and is either hinged with a snap ring or sealed, depending on the client’s needs. They also allow card inserts or information media to be placed behind the product.

Tri-fold: Clamshells are clear, custom thermoformed packaging created for retail clients to help them merchandise their products. Tri-fold clamshells give retailers the option to hang product on a peg, stand it on a shelf or arrange it in a display. They are designed with three parts which fold together and snap into a rigid package. With the triangular design, tri-fold clamshells can easily stand on their base.

Box insert: Custom thermoformed box inserts are widely used for tools, medical and food items. They are often used for insertion into shipping cartons with clear windows to hold items in place for display. A box insert is typically made of HIPS material that has minimal draft and flanges which allow it to take up less of the box it is sliding into.

Tray: A custom thermoformed tray is a multi-cavity packaging option that can serve many different functions. They can be used for stand alone store displays, medical device shipping carriers or assembly part carriers. They can also be designed as part of a larger packaging product or have lids, snap devices or just for stacking.

Pouch: A thermoformed pouch is usually described as a rectangular bag with three sides sealed prior to filling and closing. While Brookdale Plastics does not do pouches, we have a number of excellent packaging options to offer that may better fulfil your needs. Please fill out our Quick Response Form or call us right now at 1(800) 383-7092 for more information.

Injection Molding: Injection molding is when plastic granules are melted, then injected into a mold cavity to create the required component or product shape. Brookdale Plastics does not do injection molding.

However, if you are looking for plastic packaging, simply contact us by filling out our Quick Response Form or calling us at 1(800) 383-7092 so we can find a solution to your packaging needs.

Electronic: Made from special ESD materials, usually high tolerances due to components which are placed into trays. Trays are usually multi-pocketed with finger slots and are stackable.

See examples of these in Packaging Samples section >>

Brookdale Plastics Tools Back to top

What is Vista Document Management?
Vista Document Management allows engineering, sales and production to easily retrieve documents and drawings related to quotes, parts and jobs from their computer stations and production stations. Our inspectors and press operators can access drawings, benchmark production information and review quality control documents in real time from the shop floor as part of our paperless documentation system.

What is Solidworks 3D Design & CAD Software?
Solidworks 3D design software is a 2D and 3D design package that allows us to create three dimensional digital representations of packaging and molds. With these, we can accurately determine the most efficient packaging design to keep costs to a minimum. We regularly update to the latest version of Solidworks to stay on top of the latest advancements in technology.

What is PRO-E CAD/CAM Software?
PRO-Engineer CAD/CAM software is a fully integrated application that allows us to develop everything from concept to manufacturing within one application. Because of its integration with manufacturing, it automatically propagates design changes to all downstream stations.

PRO-E also gives us complete virtual simulation capabilities.

The other benefits are the automated generation of associative tooling design and machine code for manufacturing of molds and packaging and complete structural, thermal, fatigue and dynamic simulation. Brookdale Plastics regularly updates to the latest version of Pro/Engineer.

What is T-Sim computer simulation of thermoforming?
T-Sim Thermoforming digital simulation software is another important tool for keeping costs down. It gives our engineering team the opportunity to create a digital simulation of the tooling to test our design before actual production tooling is produced.

What is the Dimension 1200 SST 3D Printer (Rapid Prototyping machine)?
Our rapid prototyping machine allows us to “print” functional three dimensional ABS molds directly from our 3D computer software. We have placed the 3D printer in our lobby you can actually watch it quickly create molds for testing prototypes.

Materials Descriptions Back to top

ESD (ElectroStatic Discharge): Materials for protection and prevention of ElectroStatic Discharge (ESD). They are categorized into three separate groups; separated by their ranges of conductivity to electrical charges.

  • Anti-Static: Resistivity generally between 109 and 1012 ohms per square (for definition of ohms per square – see below). Initial electrostatic charges are suppressed.
  • Static Dissipative (SD): Resistivity is generally between 106 and 109 ohms per square. Low or no initial charges and prevents discharge to or from human contact.
  • Conductive (CN): Resistivity is generally between 103 and 106 ohms per square. Prevents initial charges and provides a path for charge to bleed off.

Ohms Per Square What?
It doesn’t matter. Ohms per square is the unit of an electrical measurement of surface resistivity across any given square area of a material. It is the measurement of the opposition to the movement of electrons across an area of a material's surface and normalized to a unit square. This measurement is intended to be a basic material parameter and not dependent on absolute area, length or thickness.

HIPS (High Impact Polystyrene): Has a high dielectric strength and is resistant to a wide variety of chemicals: alkali, salts, lower alcohols, and many acids. It also has great dimensional strength, balanced properties of impact strength and heat resistance. HIPS is easily machined, relatively low in cost and 100% recyclable.

BPI10 (Conductive High Impact Polystyrene): Is widely specified for many applications because of its bulk conductivity, durability, and ease of thermoforming.

PVC (polyvinyl chloride): Has excellent chemical resistance and dielectric properties, good tensile, flexural and mechanical strength, low moisture absorption, exceptional dimensional stability and good flammability characteristics. Virgin PVC sheets comply with Food and Drug Administration (FDA) regulations. PVC's most popular use is blister packs and insert trays.

PETG (extruded polyethylene terephtalate glycol): PETG is tough, clear, versatile, easy to work with, chemically resistant, and affordable. It provides excellent material distribution and part definition during custom thermoforming. PETG meets all current food contact legislation. Virgin PETG sheets comply with Food and Drug Administration (FDA) regulations. 

PET(polyethylene terephthalate): Is a clear, tough, stable polymer with exceptional gas and moisture barrier properties. It is often used to contain carbon dioxide (alias carbonation) in soft drinks bottles. Virgin PET sheets' compliance with Food and Drug Administration (FDA) regulations has allowed a diversity of food applications including such packaging staples as clamshells, trays and containers.

RPET (recycled polyethylene terephthalate): RPET is the result of the recycling of plastic carbonated soft drink bottles and water bottles which are almost exclusively PET. It retains most of the same attributes of PET with the added benefit of being a recycled and recyclable product. However, it is not approved for food exposure. RPET is most often used for clamshells.

HDPE (High density polyethylene): HDPE is used in a variety of applications and industries where excellent impact resistance, high tensile strength, low moisture absorption and chemical and corrosion resistance properties are required.

The two biggest advantages of custom thermoformed HDPE are toughness at temperatures as low as -180°F and the ability to withstand steam sterilization at 250°F.

PP (Polypropylene): Polypropylene is strong, yet highly elastic. Also, it is recyclable for reuse in more applications than other plastics. The ability to hot fill and microwave make polypropylene suitable for deli containers, ready meat trays and blister packs for medical and pharmaceutical packaging.

While the materials listed above is the majority of materials Brookdale Plastics uses in the manufacuture of products for its customers, there are many engineered materials that have special attributes depending on the application. If your application requires a specialty material, we will find it.

Manufacturing Terms Back to top

Sheetline: Flat plane of reference running horizontal through the machine.

Male mold: All molded features above sheetline.

Female mold: All molded features below sheetline.

Draft: The amount of angle on the side walls of a mold. The greater the draft, the easier to release the part from the mold.

Flange: Flat border around part left after trimming, larger flanges allow for better stacking.

RF sealed (radio frequency sealed): Thermoplastic materials are bonded together using radio frequency energy by employing a polyvinyl chloride buffer above and below the materials being bonded while applying pressure and radio frequency energy.

Need more information?

or call 1 (800) 383-7092

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