Vacuum / Thermoforming

Combining in-house extrusion facilities with our vacuum forming capability maintains our strong market position. We also specialise in medium size batch runs which further enables us to maintain customer satisfaction.

With state-of-the-art vacuum forming machines on site, we have the ability to tailor-make trays, pallets, bases and lids to your individual requirements.

Our thermo formed products start with design. We have many years’ experience of tool design and with our CAD capabilities, this enables us to effectively and efficiently work with the customer to come up with the best design possible. We are very experienced in selecting the right material to use and quickly establish the optimal gauge to give the lowest cost product that works.

Toolmaking is normally carried out by our approved toolmakers under our control. Prototype tools are made to produce a small number of trial products to confirm the functionality. Once confirmed, aluminium tools are made. The aluminium tools can produce many thousands of products.

Our thermoforming production is carried out using Geiss and Shelley machines. These are fitted with modern CNC controls and high-speed heaters. Supported by our in-house sheet extrusion lines less than 100m away, we can optimise production and reduce costly waste.

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Some machines have sheet loaders and some with automatically variable plate apertures.

Tooling is secured with quick release tooling clamps. These features significantly reduce the tool change over time and setting costs, this is very important and beneficial when running medium size batch production.
An additional benefit of having our own extrusion lines is that the skeletal trimmings around a vacuum formed product can be chipped and fed back into extrusion, at an appropriate percentage. This helps in our aim of reducing any waste going to land fill.

To ensure the security and safe condition of your goods and components, our moulded trays, racks and dividers provide innovative solutions to keep your items from damage during transit and storage.

The different plate sizes we can offer are; 330mm x 330mm and 12350mm x 1350mm.

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  • Product Size up to 2350mm x 1350mm x 600mm
  • Automatic Sheet Loading
  • High Energy Heating System
  • Local Toolmaking Service

Our services

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Foam insert

Foam insert is a key element to our design, product, and supply capabilities. Our understanding of your requirements and constraints is a strength of our team and the service we provide.

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Here at CPL we take responsibility for the management of all logistical procedures. We provide our own transport for the delivery of our manufactured products. Where the use of our own transport is not appropriate we employ the services of reputable handlers and carriers. We are confident to ensure the safe the efficient delivery of your customised packaging products.



At CPL, we recognise that certain manufacturers of plastic packaging offer only standard product ranges. We fill this gap by identifying the need for individualism. In providing a bespoke design service, we further demonstrate our dedication to you.

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Mirror Welding

CPL have the expertise and technology to provide Butt Fusion application, commonly referred to as Mirror Welding. This is superior to hand welding, which we also employ, Butt Fusion performs a more solid, accurate and durable welding procedure.

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Sheet Extrusion / Extruded Sheets

At CPL we are in a unique position, in that we manufacture our own high quality sheets of plastic using our own on-site extrusion machinery and technology. Using raw plastic materials in pellet form, and returned plastic that is recycled, to enable a sustainable product (by closing the loop), we can create the exact size, finish, plastic content and colour you require.