We use cookies and similar technologies to analyze site traffic and improve your experience. By continuing to browse, you consent to our use of these technologies. Privacy Policy
India's First Thermoformed
Calf Housing System
Formpack manufactures the CalfAvas modular HDPE calf pen — a flat-pack, 15-minute-assembly shelter that has achieved 0% calf mortality in its Amul GCMMF pilot. 75% cheaper than imported alternatives. Made in India, for India.
30% of India's Calves Don't Survive Their First Months
Hundreds of thousands of calves die each year from exposure, disease, and unsanitary conditions in makeshift metal mesh pens. Each calf costs a dairy farmer ₹50,000 ($600) to birth through IVF and raise. When a calf dies, a family's livelihood is devastated.
Imported plastic calf hutches (Calf-Tel and equivalents) cost $800–1,000 per unit — out of reach for the 3.6 million small dairy farmers who need them most. Metal mesh pens offer no weather protection, no ventilation control, and harbour bacteria between cohorts.
CalfAvas — The Solution
3 rear windows + 7 rib slots · Cross-ventilation by design
Engineered for India's Dairy Farms
Every feature of the CalfAvas pen is a direct result of Formpack's thermoforming expertise — geometry, material, and function designed as one.
Modular 3-Piece Design
Left wall, right wall, and back wall bolt together in 15 minutes. Each panel is individually replaceable — farmers only replace the damaged section, not the entire pen.
Indian Climate Ready
UV-stabilised HDPE withstands 45°C Gujarat summers and heavy monsoon rains. The material retains structural integrity across India's extreme seasonal temperature swings.
Built-In Ventilation
3 rear windows and 7 side rib slots provide cross-ventilation that reduces respiratory disease incidence by 60%. Airflow is engineered into the thermoformed geometry — no add-ons required.
Pressure-Wash Clean
Non-porous HDPE surface resists bacterial absorption. A standard pressure washer fully sanitises the pen between calves — critical for biosecurity on high-throughput dairy farms.
Flat-Pack Shipping
Panels nest flat for transport — 10× more units per truck than imported round-hutch alternatives. Dramatically lower logistics cost enables affordable last-mile delivery across India.
10+ Year Lifespan
5 mm HDPE with UV stabiliser package. No rusting, no rotting, no repainting. The pen outlasts multiple calf cohorts, delivering the lowest total cost of ownership in its category.
Built Tough. Sized Right.
Dimensions are optimised for Indian dairy breeds — Holstein Friesian, Jersey, Gir, Sahiwal, HF Cross, and Buffalo Murrah. The arched roof profile is thermoformed in a single shot, eliminating seams that collect moisture and bacteria.
Zero Mortality. Tested with Amul.
In our pilot with Amul GCMMF — the world's largest dairy cooperative — CalfAvas achieved 0% calf mortality versus the 30% national average.
From Pellet to Pen — Under One Roof
Formpack's vertically integrated facility in Umargam, Gujarat handles every step — from HDPE sheet extrusion to flat-pack dispatch. No outsourcing, no quality gaps.
HDPE Sheet Extrusion
Formpack extrudes 5 mm HDPE sheet in-house on our own extrusion line in Umargam. Precise thickness control and UV stabiliser compounding are managed at the pellet stage — no reliance on external sheet suppliers.
Vacuum Forming
Each wall panel is thermoformed on our large-format vacuum forming machines. The arched roof profile, rib slots, and window cutouts are formed in a single shot — no secondary joining or welding.
CNC Trimming
Panels are CNC routed to precise dimensions. Window openings, bolt holes, and drainage slots are cut to ±0.5 mm tolerance for consistent bolt-together assembly on the farm.
Quality Inspection
Each panel undergoes dimensional check, UV stabiliser verification, and surface inspection. Our 8-stage QC process ensures every pen shipped meets the CalfAvas specification.
Flat-Pack Assembly
Panels are nested flat and bundled with hardware (bolts, washers, buckets). The flat-pack format enables 10× more units per truck than assembled alternatives.
Dispatch to Farm
Finished pens ship from our Umargam facility to dairy farms across Gujarat and beyond. Formpack handles export documentation for international orders.
Vertically Integrated — Umargam Facility
Extrude → Form → Trim → Assemble → Pack → Ship. Every CalfAvas pen is made start-to-finish in our own facility — giving us full control over quality, lead time, and cost.
HDPE and Beyond
The standard CalfAvas pen uses UV-stabilised HDPE. Formpack can also supply pens in antibacterial HDPE, ABS, or ASA for specific export markets or climate requirements.
| Material | Grade | Best For | Lifespan |
|---|---|---|---|
| HDPE (Standard)STANDARD | UV-stabilised, food-safe | Standard calf pens for Indian climate | 10+ years |
| HDPE (Antibacterial) | Antimicrobial additive | High-biosecurity dairy farms, export markets | 10+ years |
| ABS | General purpose | Indoor calf housing, controlled environments | 8+ years |
| ASA | Superior UV resistance | High-irradiance outdoor installations (Middle East, Africa) | 12+ years |
Deployed. Proven. Scaling.
Two Ways to Get Pens on Your Farm
Fund a Pen — $199 (Impact Campaign)
Support the CalfAvas mission. Fund one complete pen — plastic hutch, metal fence, buckets, and delivery to a partner dairy farm. Receive GPS coordinates, deployment photos, and quarterly calf updates.
Visit fundacalf.comBulk B2B Orders — Direct from Formpack
Dairy cooperatives, NGOs, government schemes, and distributors can order CalfAvas pens directly from Formpack at volume pricing. Minimum order 50 units. Export available. Contact us for pricing and lead times.
WhatsApp us for bulk pricingEnquire About Calf Pens
Dairy cooperatives, NGOs, and distributors — contact us for volume pricing, export documentation, and custom material options.
Formpack · Umargam, Gujarat, India · ISO 9001:2015