Thermoforms thin‑ to heavy‑gauge PETG, PVC, and RPET sheet into custom clamshells, trays, and blisters, then heat‑ or RF‑seals and die‑cuts them in‑house. Inline tooling, CNC trim, and GMP traceability deliver retail‑ and medical‑grade packaging with rapid change‑over and tight dimensional control.

Heats a thermoplastic sheet until pliable, then vacuums it over a temperature-controlled mold so the sheet conforms and cools to the final geometry. Ideal for thin-gauge packaging, trays and display parts where tooling cost must stay low.

Vacuum Thermoforming

Supports high volume production demands, ensuring scalability and competitive cost for large‑scale orders.

Meets the needs of medium volume production, offering cost efficiency for expanding product lines.

Designed for prototyping and small batch runs, allowing for rapid iteration and testing.

Optimized for low volume production, ideal for market introduction and specialized products.

Uses electrically heated resistance bars that heat only during the seal cycle. The bar presses thermoplastic films or coated paperboard against an anvil, fusing a hermetic or peelable joint without excessive thermal exposure to the product.

Impulse / Hot-Bar Heat Sealing

Radio-frequency heat and pressure seal clamshell or blister packages around finished assemblies, creating tamper-evident, retail-ready or MIL-spec moisture-barrier packs. Supports PVC, PET-G, and medical Tyvek® lidding.

RF Heat-Sealing & Blister Packaging

Steel-rule and rotary die-cutting of printed polyester, polycarbonate, and adhesive laminates to produce dimension-critical labels, graphic overlays, and spacer gaskets.

Precision Die-Cutting of Labels & Overlays

Services involving assembly, sorting, and packaging of components into ready-to-use kits or sets, streamlining supply chain and logistics operations.

Packaging / Kitting

Custom Thermoformed Packaging

Orange Packaging’s fully integrated toolroom designs and machines aluminum, steel, and tooling-board molds up to 1.5 m in length. Five-axis high-speed mills, EDM, and CNC routers deliver ±0.01 mm cavity accuracy and Ra 0.2 µm finishes, while CAD/CAM engineers optimise cooling circuits and draft in-house for shorter cycle times. Rapid prototype tools ship in days, production tools in weeks—ready for thermoforming or RF-heat-seal qualification.

Precision machining, EDM and surface finishing of steel or aluminum molds and transfer pots for rubber molding applications, delivered fully spotted, vacuum-tested and ready for press qualification.

Mold Fabrication (Tool & Die)

Family/multi-cavity tools for continuous production

Tooling Design involves engineering and developing specialized tools, molds, dies, and fixtures used in manufacturing processes to ensure precision, repeatability, and efficiency. High-quality tooling is crucial for achieving tight tolerances, consistent part quality, and optimized production efficiency across industries like automotive, aerospace, electronics, and medical devices.

Tooling Design

3-Axis Vertical Machining uses a vertical-spindle CNC mill with linear X-, Y-, and Z-motions to produce prismatic parts, slots, pockets, drilled holes, and 2.5-D contours. Tool changers, rigid tapping, and on-board probing enable accurate, repeatable machining of small- to mid-sized components with positional accuracy to ±0.010 mm and surface finishes to Ra ≤ 0.8 µm.

3-Axis Vertical Machining

3- or 5-axis routing of polyurethane/epoxy tooling board to create prototype molds, drape-form fixtures and styling models with short lead-times and low cost compared to aluminum.

CNC Router Tooling-Board Fabrication

Utilizes additive manufacturing technologies to quickly fabricate tooling components, significantly accelerating prototyping, testing, and initial production phases.

Rapid 3D-Printed Tooling

CNC machining, EDM and polishing of hardened tool-steel or carbide extrusion dies and mandrels, delivered ready for production with flow-balance verification and bench proofs.

Die Manufacturing (Tool & Die)

In-House Tooling & Mold Manufacturing

Orange Packaging fuses ArtiosCAD/SolidWorks structural engineering with large-format digital print, rotary die-cut, CNC acrylic routing and ISTA-certified load testing to deliver pallet-load, end-cap and countertop POP displays. Rapid 24 h prototypes, multi-material integration and in-house pack-out lines compress concept-to-launch timelines while ensuring retailer compliance and floor-ready durability.

Structural and graphic engineering service for corrugated, acrylic and mixed-material point-of-purchase (POP) displays—including CAD design, stress analysis, prototyping and retailer compliance documentation.

POP Display Design & Engineering

Converts printed or plain corrugated sheets into custom displays using rotary die-cutting, digital cutting and high-speed gluing lines, delivering flat-packed or pre-assembled units ready for merchandising.

Corrugated POP Display Fabrication

Loads finished merchandise into POP displays, secures components, applies instruction sheets and master-packs the units for direct-to-store shipment under retailer guidelines.

Display Loading & Pack-Out

High-speed CNC routing of cast or extruded acrylic sheets to produce precise profiles, slots and pockets while leaving flame-polished edge quality ready for display use.

Acrylic CNC Routing & Cutting

POP Display Design & Fabrication

Orange Packaging’s acrylic display cell combines high-speed CNC routing, CO₂ laser cutting, strip-heat bending and optical-grade flame polishing to deliver retail-ready components with museum-quality edges. Integrated electrical benches install LED edge-lighting, while in-line buffing achieves 0.5 µm Ra finishes that rival cast surfaces. The fully enclosed dust-capture and vacuum fixturing system maintains ±0.05 mm repeatability across sheets up to 1.3 × 2.44 m.

Supports high volume production demands, ensuring scalability and competitive cost for large-scale orders.

Localized strip heaters or ovens soften acrylic, allowing precise bends, folds or drape-forms around fixtures without crazing or loss of optical clarity.

Acrylic Heat-Bending & Forming

Non-contact cutting of acrylic, polycarbonate, PET-G and thin films using sealed-tube CO₂ lasers (9.6 / 10.6 µm) to produce micro-kerf cuts with flame-polished edges and minimal burring.

CO₂ Laser Cutting (Plastics)

Polishing / Grinding encompasses abrasive stock-removal and surface-refinement operations applied after rough machining or heat treat. Grinding with bonded-abrasive wheels (Al₂O₃, SiC, CBN, diamond) brings parts to final size, geometry, and flatness, routinely holding ±0.002 mm and roundness < 0.001 mm on hardened steels > 60 HRC. Subsequent polishing stages—belt, buff, super-finishing, micro-finishing, or lapping—reduce surface roughness to Ra 0.05 µm–0.20 µm, produce plateau finishes for bearing surfaces, or achieve mirror cosmetics before coating or plating. Coolant-flooded machines, automatic size-control gauging, and filtered oil or water emulsions ensure thermal stability and contamination-free finishes for aerospace, medical, mould-and-die, and precision fluid-power components.

Polishing / Grinding

Builds complete wire-loom and panel assemblies using automated cut/strip/crimp machines, continuity/hipot test, and lot-level traceability for electromechanical products.

Electrical & Cable-Harness Assembly

Acrylic Display Fabrication

Orange Packaging operates a 150 000 sq-ft, climate-controlled fulfillment center that assembles kits, loads and shrink-wraps retail displays, palletizes to ISTA standards, manages bar-coded inventory, and drop-ships worldwide with EDI/ASN compliance. Vision-verified pick-to-light cells and stretch-wrapper tunnels ensure ≤0.2 % pack-out error while maintaining >98 % on-time-delivery performance.

Value-Added Services (VAS) encompass a suite of post-manufacturing activities that enhance the finished product and streamline supply-chain fulfillment. Typical services include light mechanical or electromechanical assembly, kitting, custom packaging and labeling, product personalization, logistics coordination, and final inspection/testing for regulatory compliance. VAS operations are highly configurable to meet unique customer requirements, reduce total landed cost, and accelerate time-to-market.

Value Added Services

Nationwide launches or continuous replenishment

Provides torque-controlled mechanical assembly, precision press-fit and staking, and colour-coded kitting cells that consolidate lot-tracked hardware into turnkey, line-side-ready packages. Integrated pick-to-light guidance, ESD-safe workstations, and barcode/QR traceability ensure every fastener, sub-component, and completed kit meets specification and ships with full documentation.

Mechanical Assembly & Kitting

Encloses single items or multipacks in shrink film followed by automated heat-tunnel shrinking, then unitizes cases onto pallets with stretch-wrap or strapping for transport.

Shrink Wrapping & Palletizing

Vendor Coordination & Supply-Chain Management orchestrates multi-tier suppliers—covering RFQ aggregation, PO release, expediting, quality surveillance, and logistics—to deliver complete assemblies or projects on time and within budget. The service provides a single point of contact that mitigates risk through supplier qualification, capacity planning, and real-time status reporting.

Vendor Coordination & Supply-Chain Management

Inventory Management & Logistics plans, stores, packages, and ships finished parts using JIT, Kanban, and blanket-order strategies to optimize customer supply chains and reduce total landed cost.

Inventory Management & Logistics

Packaging Fulfillment & Logistics

Indicates that products are manufactured in the United States, meeting federal guidelines for domestic origin claims.

Made in USA (Domestic Manufacturing)

A global standard for quality management systems focusing on continuous improvement and customer satisfaction.

ISO 9001:2015

U.S. FDA clearance confirming that an additive used in food-contact packaging or processing equipment is safe under intended conditions of use, as demonstrated through a Food Contact Substance Notification (FCN) or applicable 21 CFR indirect additive regulation.

FDA Food Contact Substance (FCS) Clearance

Demonstrates that food-contact materials and articles comply with Regulation (EC) No 1935/2004 and related implementing measures (e.g., EU 10/2011 for plastics), ensuring they do not endanger human health or alter food composition.

EU Food Contact Materials Compliance (EC 1935/2004)

Active membership in the Council of Industry, a regional association that provides advocacy, workforce development, training, and networking for manufacturers in New York’s Hudson Valley.

Council of Industry of Southeastern New York (COI) Membership

The development, manufacturing, and supply of precision-engineered medical systems, devices, and critical components, including diagnostic equipment, surgical instruments, implantable devices, laboratory systems, and precision medical components. Emphasizes adherence to ISO 13485 and FDA QSR standards, traceability requirements, sterile processing, rigorous validation, and use of biocompatible materials such as titanium, stainless steel, and medical-grade polymers to ensure patient safety and clinical effectiveness across global healthcare settings.

Medical Devices & Healthcare Equipment

Orange Packaging delivers precision thermoformed medical-grade packaging and assembly services for the Medical Devices & Healthcare Equipment industry, supporting sterile processing and contamination control with cleanroom manufacturing and FDA-grade materials.

Machinery, components, and smart-farming systems for modern field and indoor agriculture—tractors, harvesters, irrigation, hydroponic racks, and sensor platforms. Durability, efficiency, and data-driven performance support high-yield, sustainable agribusiness operations.

Agriculture & AgriTech

Orange Packaging provides custom thermoformed packaging and display fabrication for the Agriculture & AgriTech industry, including specialized packaging solutions for vertical and indoor farming to maintain product integrity from farm to consumer.

High-volume manufacturing of household appliances, personal care devices, and durable consumer products. UL / CE safety, energy-efficiency targets, and cost-optimized injection molding and assembly lines meet global retail quality expectations.

Consumer Goods & Appliances

Orange Packaging offers high-end acrylic fabrication and thermoformed packaging solutions for the Consumer Goods & Appliances industry, creating visually appealing and durable POP displays and packaging that enhance product presentation and brand value.

The design, fabrication, and assembly of diverse products across multiple end‐use industries or specialized, project‐based needs. Emphasis is on versatility, custom solutions, and broad expertise to handle unique or varied manufacturing projects outside of more narrowly defined sectors.

General Manufacturing

Orange Packaging specializes in versatile manufacturing including precision thermoforming, mold creation, finishing, and assembly for General Manufacturing applications, delivering custom packaging and display solutions tailored to diverse industry needs.

Rigid, flexible, and specialty packaging; high-speed printing and labeling technologies. Efficiency, sustainability, and regulatory compliance drive solutions that protect products and communicate brand value across FMCG, pharma, and industrial supply chains.

Packaging, Printing & Labeling

Orange Packaging manufactures precision thermoformed packaging and POP display components for the Packaging, Printing & Labeling industry, providing custom, FDA-grade, and biodegradable packaging solutions that protect and present products effectively in retail and consumer markets.

Machinery, filling, and packaging solutions for meat, dairy, beverage, and ingredient lines. USDA / FDA sanitary design, corrosion-resistant materials, and high-throughput automation preserve product quality and safety in regulated processing environments.

Food & Beverage Processing

Orange Packaging produces FDA-compliant thermoformed packaging and assembly solutions for the Food & Beverage Processing industry, ensuring freshness, protection, and compliance for snacks, ready-to-eat meals, and perishable goods through their in-house design and manufacturing capabilities.

Founded in 1950, family-owned Orange Packaging thermoforms, die-cuts, and assembles custom plastic packaging and point-of-purchase displays entirely in Newburgh, NY. 150 000 ft² across two ISO 9001:2015-certified plants houses ten high-tonnage thermoforming lines, in-house CNC mold machining, RF/heat sealing, acrylic fabrication, and Pack It Here™ fulfillment. Domestic, FDA food-contact and EU 1935/2004 compliant production plus a patented biodegradable additive deliver sustainable trays, clamshells, and retail displays within 2–6 weeks, backed by 75 years of responsive, family-run service.

This 100 000-ft² headquarters houses design offices, CNC mold shop, ten high-tonnage thermoforming and RF/heat-sealing lines, and Pack It Here fulfillment under one roof. Located minutes from I-87/I-84 and Stewart International Airport, it offers single-site, ISO 9001-certified production with rapid Northeast distribution.

Orange Packaging Headquarters – 1 Favoriti Ave

The 50 000-ft² Broadway plant expands thermoforming capacity, large-format cutting, and finished-goods warehousing. Situated on NY-Route 9W with easy truck access, it mirrors HQ capabilities and supports high-volume runs, seasonal surges, and regional drop-shipping, all under the same ISO 9001 quality system.

Orange Packaging Broadway Plant – 840 Broadway

ISO 9001-certified New York thermoformer delivering custom packaging & POP displays in 2–6 weeks.

Orange Packaging

Thermoformed Packaging & Retail Displays

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