Built for the production line.
Custom mold design, thermoform tooling, machine retrofits, and spare-part supply for food, pharma, and industrial packaging lines.
Request a quoteEngineering behind the line
BioFlex specialises in the mechanical engineering behind packaging production, from new mold and tooling design through to spare-part reverse engineering, machine modifications, and line integration. Our packaging work spans food, pharmaceutical, and industrial applications. We are not tied to a single material or format: if it runs on a packaging line and needs an engineering solution, we can scope it.
Services
- Thermoform mold design and manufacture
- Forming, sealing, and cutting tooling.
- Custom container and tray design
- Design-for-manufacture for thermoform constraints.
- Spare-part reverse engineering and supply
- Knife sets, mold inserts, conveyor parts, guards.
- Machine modifications and upgrades
- Format changes, output rate improvements, hygienic-zone upgrades.
- Automated filling line integration
- Robotic pick-and-place for solids, dosing systems for liquids.
- Safety guarding and interlocks
- Designed to EN ISO 13849 and machinery directive standards.
- Pharmaceutical and industrial packaging tooling
- Blister tooling, strip packaging, industrial tray systems.
- Full machine retrofits
- Re-cladding, ergonomic operator interfaces, hygienic-design enclosures.
Why choose us
- Hands-on thermoform experience
- Three years building this equipment full-time, plus industrial design follow-on.
- Concept-to-commissioning
- One team from idea to running line.
- Faster turnaround than OEMs
- For spare parts and modifications.
- Cost-effective tooling supply
- Tooling made to our drawings and checked against our tolerances.
Recent packaging engineering projects.
From CAD design to manufactured component. A selection of tooling projects delivered for thermoform packaging lines.
Concept to manufacture
Fig. 01
Design
ManufacturedCustom cutting blade inserts
From CAD design to manufactured tool. BioFlex designed a set of custom cutting blade inserts for a thermoform packaging line, modelled in SOLIDWORKS with full design-for-manufacture review. The blade geometry was optimised for clean separation of formed packaging trays at line speed, with mounting features matched to the existing tool block to allow direct retrofit. The finished blades were CNC-machined from hardened tool steel to the dimensional tolerances and surface finish specified at design stage, ready for direct installation on the customer's line. From concept to finished tool in weeks.
SOLIDWORKS · Hardened tool steel · CNC machined · Direct retrofit · Concept to manufacture in weeks
Custom packaging design
Fig. 02
Custom thermoform packaging trays
Custom thermoform tray designs developed for retail product packaging, combining secure product retention, clear visibility for display, and efficient stacking for transport and storage. Each tray was designed around the specific geometry of the customer's product, with cavity placement optimised for material efficiency and forming consistency. Both designs were modelled in SOLIDWORKS with design-for-manufacture review to ensure compatibility with standard thermoform line speeds and tooling constraints.
SOLIDWORKS · PET / PETG compatible · 4-cavity layout · Product-specific geometry · Retail-ready
Machine upgrade
Fig. 03
HEPA-filtered full-cycle packaging line
A full-cycle automated thermoform packaging line was upgraded with integrated HEPA filtration units along the forming, filling, and sealing zones, effectively converting the line into a semi-cleanroom production environment. The upgrade enables the customer to package products requiring elevated hygiene control without the cost of relocating the line into a dedicated cleanroom facility. The retrofit also included anti-static bars at the foil entry point and a top-foil UV station for surface treatment before sealing, improving overall product quality and reducing contamination risk.
HEPA filtration · Anti-static integration · UV sealing zone · Semi-cleanroom upgrade · Full-cycle retrofit
Need a mold, spare part, or line modification?
Send us a description or drawing. We'll respond within 5 business days.