Our Manufacturing Process
A fully integrated 5-step automated workflow—from Sheet Extrusion and Thermoforming through Automated Production, Quality Checks, and Packaging & Dispatch.
5-Step Precision Manufacturing Process
Ace Packaging operates advanced polymer processing infrastructure across two manufacturing units in Daman, India. Every container is crafted through an automated sequence ensuring certified food-grade purity, structural perfection, and zero transit leakage.
Sheet Extrusion
Precision Gauge Polymer Sheet Production
100% prime virgin food-grade polymer resin (PP 05 / PET) is dehumidified, melted, and continuously extruded through a high-precision flat die. Multi-roll calendar stacks cool and calibrate the sheet with laser-monitored gauge uniformity across the entire web width.
Thermoforming
Plug-Assist Cavity Forming & Hermetic Rim Shaping
The extruded plastic sheet is indexed into computer-controlled radiant heating zones and vacuum-formed with precision plug-assist tooling. Container walls, partition ribs, and hermetic rim snap grooves are formed with micro-tolerance repeatability.
Automated Production
High-Speed Inline Trimming & Robotic Handling
Formed containers are trimmed directly in-mould with CNC accuracy. High-speed 3-axis robotic arms extract finished containers onto cleanroom conveyors without manual human touch, while web skeleton trim is granulated inline for closed-loop sustainability.
Quality Checks
100% Inline Optical Vision & Rim Leak Testing
Every production batch undergoes multi-point inline inspection. High-speed vision cameras detect micro-pinholes, perimeter wall thickness is gauged, and containers undergo 100% rim seal drop and leak testing under hot liquid transport simulation.
Packaging and Dispatch
Hygienic Polybag Sleeving & Global Export Logistics
Containers are automatically counted, nested, and sealed into protective dust-proof polybag sleeves directly at the conveyor exit. Sleeves are packed into heavy-duty 5-ply corrugated cartons, palletized, stretch-wrapped, and barcoded for domestic and global export dispatch.
1,500,000+ Units Daily
Massive industrial moulding capacity across high-speed robotic injection and thermoforming presses, fulfilling containerload export and bulk franchise orders with zero delay.
Daman Manufacturing Campus
Unit 1 and Unit 2 in Dabhel, Daman feature dust-controlled cleanroom halls, CNC mould tooling workshops, and automated optical micrometer quality laboratories.
ISO 9001:2015 Certified
Audited and certified by SGS United Kingdom Ltd (Certificate IN25/00000652), ensuring 100% prime virgin polymers, zero chemical migration, and food contact safety.
Inspect Our Manufacturing Lines in Person
We welcome corporate procurement heads, brand managers, and export buyers for scheduled on-site audits at our Daman manufacturing campus. Request free physical sample kits or review our official ISO 9001:2015 audit file.