For decades, aluminum trays have been a standard in food packaging for frozen foods, bakery items, and prepared meals. But in today’s environment of volatile global supply chains, tariff uncertainty, and growing sustainability pressures, many food manufacturers are evaluating paperboard trays as an aluminum tray alternative.
Dual-ovenable paperboard trays now deliver the performance manufacturers need while helping reduce sourcing risk and support sustainability goals. At PaperTech, we work with food manufacturers exploring this transition as supply chain pressures and regulatory expectations continue to evolve.
ALUMINUM SUPPLY CHAIN RISK
Aluminum is a globally traded commodity subject to price swings, geopolitical risk, and import dependency. Much of the aluminum packaging used in the U.S. food industry relies on overseas production, exposing manufacturers to tariffs, port delays, and transportation disruptions.
For food manufacturers operating on tight production schedules, supply chain reliability is critical. When packaging materials are sourced internationally, responding to unexpected delays becomes far more difficult.
THE ADVANTAGE OF DOMESTIC PAPER TRAYS
Domestically manufactured paperboard trays provide a more predictable sourcing model. Paper trays produced in the United States reduce dependence on international shipping and help avoid many of the tariff risks associated with imported aluminum packaging.
Key advantages include:
For procurement teams responsible for maintaining production continuity, these advantages help reduce operational risk.
DUAL-OVENABLE PAPER TRAYS FOR FREEZER-TO-OVEN APPLICATIONS
A common question when evaluating paper trays vs. aluminum trays is performance. Today’s dual-ovenable paper trays are engineered to withstand the full production cycle—from high-speed processing and freezing to microwave or conventional oven heating.
Paper trays are widely used across frozen meals, bakery products, pizza, and prepared foods. Available formats include round, square, and rectangular trays, allowing manufacturers to transition away from aluminum without sacrificing functionality or product presentation.
SUSTAINABILITY AND REGULATORY MOMENTUM
Paperboard trays also support the growing sustainability goals of food manufacturers and retailers. Fiber-based packaging made from responsibly sourced paperboard can align with retailer sustainability commitments while supporting compliance with emerging regulations such as Extended Producer Responsibility (EPR) programs and foam bans.
As sustainability reporting and packaging regulations evolve, paper-based packaging offers manufacturers a solution that supports both environmental goals and operational performance.
MAKING THE TRANSITION
Switching from aluminum trays to paperboard trays requires evaluation, including line compatibility and qualification testing. However, manufacturers working with experienced suppliers often find the transition smoother than expected.
At PaperTech, our engineering team works directly with food manufacturers to evaluate production lines and help ensure a seamless transition from aluminum to paper trays.
THE BOTTOM LINE
Paper trays are no longer a niche alternative to aluminum packaging. Today’s dual-ovenable paperboard trays provide reliable performance for frozen foods, bakery products, and prepared meals while offering a more stable domestic supply chain.
PaperTech manufactures dual-ovenable pressed paperboard trays in the United States from a 150,000-square-foot facility in Ohio. With more than 25 years of paperboard expertise, we help food manufacturers transition to reliable, domestically produced tray solutions.
For food manufacturers evaluating an aluminum tray alternative for frozen foods, bakery items, or prepared meals, PaperTech provides a reliable packaging solution that supports both performance and supply chain stability.
Contact PaperTech to learn how paper trays could replace aluminum in your food packaging applications.
