Custom thermoforming · Noida, India · Since 1999
Vacuum-formed trays, blisters, clamshells and inserts in A-PET, rPET, PVC and HIPS — designed, tooled and produced at our Noida plant for electronics, pharma, medical device, cosmetics and industrial brands across India.
Send a photo of your product. Most enquiries are answered within the hour on a working day, and always inside 12.
Packaging we form leaves our plant inside products sold by —
The short version
Thermoforming is a process where a plastic sheet is heated until pliable and formed over a mould. Eagle Thermo Packaging is a custom thermoforming manufacturer at C-76, Sector 8, Noida, India, operating since 1 April 1999 as part of the Eagle Pack Group.
We produce custom vacuum-formed trays, blisters, clamshells, inserts and liners in A-PET, rPET, PVC and HIPS, at sheet thicknesses from 200 to 2000 micron, with a maximum forming area of 600 × 600 mm and draw depth up to 75 mm. Monthly capacity is approximately 10 lakh (1 million) pieces. Production moulds are cut in aluminium in our own toolroom, with wooden trial moulds used to prove the shape at sampling stage. Moulds start from ₹25,000.
We serve electronics, pharmaceutical, medical device, cosmetics, food and confectionery, baby care, and automotive and industrial clients across Delhi NCR and India, and supply export houses in the Noida Special Economic Zone (NSEZ). We have been audited and approved as a supplier by IKEA, Pigeon, Healthium, Auxein and Minda Corp. Over 50% of our output runs on recycled material.
Every part is custom-made to the client's product — we do not sell an off-the-shelf catalogue or sample kits. To begin, send a photo of your product or a drawing on WhatsApp at +91 98188 81811, or email pulkit@eaglepack.in.
What we make
Five families of custom part: device and product trays, blisters, clamshells, insert trays, and component or dunnage trays. Every one is tooled for a single product — send us the part and we work backwards from it.
Multi-cavity trays that hold a product in one position through transit, handling and the sealing line. Formed to your part, tolerance-checked against a physical sample.
Face blisters and folding blisters that seal to a printed card. Deep-draw detail, hang-hole options and tamper-resistant formats.
Hinged, tri-fold and slide clamshells formed as one piece with a living hinge. Built to survive a supply chain and still sell on a hook.
The tray that sits inside the box. Cavity layouts built around your piece count, in clear, white, black, gold or metallised finish.
Nesting, stacking trays that move components between stations or between plants without damage. Returnable or single-trip.
Send a photo. Our engineer will tell you what we'd form, in which material, and at what gauge — before you spend anything.
Blister formats
There are seven formats in common use, and they differ mainly in how the pack closes — heat seal, trapped card, sleeve, fold-over, hinge, or a tray dropped into a box. The right one depends on your sealing equipment, the tamper resistance you need, and how the product has to present on shelf.
The classic. A formed cavity with a flange around it, heat-sealed to a printed card. Product visible, card carries the branding and the hang hole.
The blister is trapped between two card layers rather than sealed to one. Both card faces print, and no sealing equipment is needed at your end.
The loaded blister slides into a printed sleeve. Simplest to pack by hand, easiest to change artwork on, and the lowest equipment barrier of all.
One formed piece folded over on itself and sealed along the edge. No card needed at all. We punch and fold these in-house.
A single formed piece with a living hinge that closes on itself. Hinged, tri-fold and slide variants — tri-fold stands unsupported on shelf.
A formed tray with a velvet flock finish applied into the cavities. The product sits on a soft surface instead of bare plastic, which stops scuffing on polished or plated parts and lifts a pack from functional to premium.
The formed tray that sits inside a rigid or folding carton. Cavity layout built around your piece count, in clear, white, black, gold or metallised.
Industries we serve
Electronics, pharmaceutical and medical devices, cosmetics and personal care, baby care, food and confectionery, and automotive and industrial — across Delhi NCR, the rest of India, and NSEZ export houses.
Anti-static and conductive-grade trays for boards, connectors and sub-assemblies, formed to nest and stack for line-side feeding.
Trays for orthopaedic implants — bone screws, pins and wires, plates and the metalwork that holds a fracture while it settles — plus surgical instrument trays and device blisters. Formed in our controlled room with segregated material handling and batch traceability. Audited by Healthium and Auxein.
Shelf-grade blisters and insert trays where finish matters as much as fit. Clear, metallised and coloured options.
Bottle, teat and soother packs formed under hygiene protocol in the controlled room. Audited and approved by Pigeon.
Chocolate and mithai inserts, bakery and cake-box trays, gift assortments — formed from food-contact-grade sheet with material documentation.
Component and dunnage trays that move parts between stations without damage. In market with Minda Corp, Minda Silca and Egelhof.
Materials & capabilities
We form four materials — A-PET, rPET, PVC and HIPS — from 200 to 2000 micron, and two of those four (rPET and HIPS) are recycled as standard. Each has its own usable gauge window, and picking the wrong one is the most expensive mistake you can make before a tool is cut. Most quoting mistakes in thermoforming are material mistakes, so here is how we actually choose.
| Material | Typical gauge | Looks like | Best for | Recyclability in India | Watch out for |
|---|---|---|---|---|---|
| A-PET | 200–800 µ | Glass-clear, stiff, good gloss | Medical trays, premium retail, food contact | Best — clear PET is the most wanted stream | Costs more than PVC; needs correct drying |
| rPET | 200–800 µ | Near-clear, very slight tint | Retail clamshells, inserts, brands with EPR targets | Best — and it counts toward your recycled-content obligation | Food contact needs FSSAI-approved FCM-rPET resin |
| PVC | 200–1200 µ | Clear, softer, forms fine detail | Face blisters, deep draws, detailed cavities | Poor — contaminates the PET stream | Increasingly refused by export and MNC buyers |
| HIPS | 300–2000 µ | Opaque — white, black, gold, metallised | Chocolate and gift inserts, dunnage, component trays | Already recycled — the HIPS we form is recycled material, with a self-certified declaration | Not transparent — choose A-PET or rPET when the product has to be seen |
Every quote we give is really an argument about these six numbers. Draw depth drives wall thinning, wall thinning drives the starting gauge, gauge drives the material cost, and the flange land decides whether your sealing line runs clean or throws rejects all shift. Get them right on paper and the tool works first time.
A female (cavity) mould forms the sheet into a recess, so dimensional detail lands on the outside face — the right choice when the outer appearance and fit into a carton matter. A male (plug) mould forms the sheet over a raised shape, putting the detail on the inside face — the right choice when the cavity has to grip a product precisely.
We make production moulds in aluminium, in-house, and prove the shape first with a wooden trial mould — which is far cheaper to change if the first sample shows something we want to improve.
Controlled-environment forming
Because when packaging touches a device, a feeding bottle or an infant teat, the question stops being can you make it and becomes where was it made, who touched it, and can you prove it. Five multinationals have come to Noida and checked.
How it works
Six steps, from your product in our hand to the first pallet. One engineer stays with your job the whole way — no portal, no ticket number.
Post us the product, or send photos and rough dimensions on WhatsApp. Either works to start.
Day 0Material, gauge, cavity layout and draw depth. We tell you what will form well and what will fight us.
Same dayA wooden trial mould proves the shape at a fraction of the tooling cost — and that cost is adjusted against the final mould.
Cost adjusted laterYou get formed samples with your actual product sitting in them. Nothing moves until you say yes.
Your callProduction mould cut in our own toolroom to the approved design, at the cavity count that suits your volume.
~1 weekYour tool stays racked with us. Repeat orders skip straight to forming.
2–3 weeksSend a photo. Our expert will advise on material, gauge and design — free, and before you spend anything on tooling.
Work we've done
Four representative examples of the briefs that come through the door. Client names withheld where the work is confidential.
Medical devices
The existing tray let screws rotate and shift on the road, so parts arrived scuffed and the count was hard to verify. We deepened the cavity, added a retention rib and moved the job into the controlled room. CONFIRM DETAILS
Baby care
Flange width was inconsistent, so seals failed intermittently at the customer's line speed. Re-cut the tool with a wider, flatter flange and the rejects stopped. CONFIRM DETAILS
Confectionery
Brand needed a premium multi-cavity insert and recycled content it could document. Formed in recycled HIPS with a self-certified declaration — same look, same piece price, and it counted toward their filing. CONFIRM DETAILS
Automotive
Components were shipping in loose cartons. A nesting tray designed around the part let the same pallet carry substantially more, cutting freight per unit. CONFIRM DETAILS
Recycled content & EPR
From FY 2026-27, Category I rigid plastic packaging — which is what a thermoformed tray, blister or clamshell is — must contain at least 40% recycled material, rising each year. Over 50% of what we already produce is recycled.
Straight answers
There isn't a single number, and any supplier who gives you one without seeing the part is guessing. Minimum order is driven by the dimensions: how many cavities fit on a sheet decides everything downstream. A small insert might nest eight-up, a deep-draw device tray two-up. Same sheet, same machine time, four times the pieces.
Send us the part or a photo with rough dimensions and we will tell you where the sensible starting quantity sits and why it sits there.
Thermoforming moulds at Eagle Thermo start from ₹25,000. Where a specific tool lands above that depends on part size, cavity count, draw depth and how much detail the cavity carries.
We prove the shape on a wooden trial mould first, which costs considerably less than the production tool — and that cost is adjusted against the final tooling once you approve the sample. So the trial stage is not money spent twice.
For context, this is a small fraction of what an equivalent injection mould costs, which is the whole reason thermoforming suits packaging and low-to-medium volumes. Moulds are made in our own toolroom, so a design change is a conversation with the floor rather than a negotiation with a third-party toolmaker.
The tool is cut for your part and it is yours — we do not run your tool for anybody else. It stays racked at our plant so repeat orders go straight to forming instead of waiting on tooling again. If you ever move production elsewhere, we'll talk about it like adults.
Once the mould is approved it is about a week to finish the tooling, then two to three weeks for production. Before that sits the design and sampling stage, which depends mostly on how quickly samples get approved at your end.
Repeat orders skip the whole first half. Your tool stays racked with us, so a repeat goes straight to forming.
Tell us your launch date at the first conversation rather than the last. It is usually the constraint we can design around, and almost never the one we can fix afterwards.
Yes, and it's a large part of what we do. Send a physical sample of the existing tray along with the product it holds. We'll reverse-engineer the cavity — and usually find something worth improving on the way, like a wall angle that's jamming your line or a material that costs less and performs the same.
Yes to both. We form food-contact-grade sheet for confectionery, bakery and gift applications and supply the material documentation that comes with it. Over 50% of our overall output runs on recycled material, and for recycled content in direct food contact there is now a specific FSSAI route (FCM-rPET) with approved resin suppliers that we can source to.
Piece price is built from four things: the sheet area your part consumes (part size plus trim, divided by how many cavities fit on a sheet), the material and its gauge in microns, the forming and trimming time, and the run length — longer runs spread setup across more pieces.
Tooling is quoted separately and once. This is why two trays of the same size can differ substantially in price: a deeper draw needs thicker sheet, and a part that only fits three-up on a sheet costs more per piece than one that fits six-up.
Vacuum forming is a type of thermoforming, and it's the type we do. The sheet is heated until pliable, then air is drawn out from beneath the mould so atmospheric pressure presses the sheet onto the shape. Negative pressure — nothing is blown in.
For packaging this is usually the right answer: tooling costs a fraction of an injection mould, changeovers are quick, and runs of a few thousand pieces stay economic instead of only making sense at a hundred thousand.
No. The 2022 ban targets single-use disposable items — cutlery, straws, plates, cups and disposable serving trays — not thermoformed product packaging. Trays, blisters, clamshells and inserts continue to be manufactured and sold legally.
What has changed is recycled content: from FY 2026-27, rigid plastic packaging must contain at least 40% recycled material, rising each year. That's the rule worth planning around.
Why Eagle Thermo
IKEA, Pigeon, Healthium, Auxein and Minda Corp have each inspected this plant against their own supplier standards. An audit you survived is worth more than a certificate you bought.
Aluminium production moulds and wooden trial moulds are both cut in our own toolroom at Sector 8. Nothing is sent out. A design change is a walk to the next room, not a negotiation with a third-party toolmaker and a fresh lead time.
We'll tell you when a wall is too vertical to draw, when a cavity will trap the part, and when a cheaper material does the same job — before the tool is cut.
Over half our output already runs on recycled material. As recycled-content rules tighten each year, you're not starting a project — you're continuing one.
Sector 8, twenty minutes from most of Delhi NCR, with pan-India dispatch and NSEZ export houses on the doorstep. If you want to see where your packaging is formed before you commit, walk in.
The same family has run this plant since 1 April 1999, as part of the Eagle Pack Group. You deal with owners, not account managers — and owners answer for what leaves the gate.
Start here
A photo and rough dimensions is enough to begin — you don't need a drawing, and you don't need to know the material. You'll get a real answer from someone who forms plastic for a living, usually within the hour.
Five fields. A photo helps more than a paragraph. Answered within the hour, most working days.
Pulkit will come back to you on WhatsApp — usually within the hour on a working day.
So the right person picks up your message, and so we can call you back if WhatsApp drops.
