Plastic Tray Packaging Suppliers

Plastic food trays are primarily produced by thermoforming — where a flat plastic sheet is heated and formed into the tray shape under vacuum or pressure. The main materials for food trays are CPET (crystalline polyethylene terephthalate), PP (polypropylene), BOPS (biaxially oriented polystyrene), and rPET (recycled PET). CPET trays are produced from heat-set crystallised PET — capable of withstanding oven temperatures up to approximately 220°C, making them the standard format for ready-meal trays sold for oven reheating at retail. CPET trays also tolerate microwave heating and freezer temperatures, making them suitable for cook-from-frozen ready meals. PP trays are microwave-safe and dishwasher-safe but not suitable for conventional oven heating. They are the dominant format for MAP-sealed fresh meat, poultry, and deli products at retail, and for takeaway and food service hot-fill applications. BOPS trays offer excellent clarity for retail display of salads, sushi, deli items, and fresh-cut produce — but PS is facing regulatory pressure due to poor recyclability in most markets. rPET trays (thermoformed from recycled PET sheet) are increasingly specified by supermarket buyers to meet recycled content requirements — providing equivalent functionality to virgin PET trays with certified recycled content. BRCGS Packaging Materials certification and a Declaration of Compliance under EU Regulation 10/2011 are required from all food-grade tray manufacturers.

Modified atmosphere packaging (MAP) is a technique used to extend the shelf life of fresh foods — particularly fresh meat, poultry, fish, and prepared produce — by replacing the air inside the sealed tray with a controlled gas mixture (typically a blend of CO₂, O₂, and N₂). MAP trays require a smooth, flat sealing flange that accepts a lidding film sealed hermetically under the controlled atmosphere. The lidding film must be compatible with the tray material (a PP tray requires a PP-compatible peel seal layer; a PET tray requires a PET-compatible lidding film) and must provide the required barrier to maintain the gas atmosphere during shelf life. For retail-ready packaging, trays are specified with label area dimensions, a defined sealing flange width, and a stackable or non-stackable profile — confirm all dimensions against the retailer's or buyer's shelf specification. For food service tray applications (take-out containers, school meal trays, airline catering trays), the key specifications are compartment configuration, fill volume, and stackability for transport and storage efficiency. MOQs for stock-size thermoformed trays are typically 5,000–50,000 units per specification; custom sizes require new thermoforming tooling at $500–5,000 depending on tray size and complexity.