Frequently Asked Questions

The most widely used food tray substrates in food processing are paperboard, foam, plastic and aluminum. Each has a different performance profile:

• Paperboard is produced from renewable wood fiber and is widely recyclable. With dual ovenable coatings, pressed paperboard trays perform across a broad range of food processing applications — including frozen food, prepared meals, bakery, pizza, fresh protein and fresh produce. Paperboard combines dual-ovenable performance, recyclability and high-speed line compatibility in a single material.
• Foam offers a low converted unit cost and adequate moisture resistance, making it the historical default for fresh protein and produce trays at retail. It is not ovenable, and is under active regulatory pressure at the state and federal levels.
• Plastic offers oven compatibility and strong moisture resistance, making it a common choice for frozen meals and entrée trays that require reheating. Plastic is technically recyclable but rarely recycled in practice due to limited consumer-accessible infrastructure. It is derived from fossil fuels and carries growing regulatory and retailer sustainability scrutiny.

Aluminum provides a moisture and oxygen barrier and handles the full temperature range — freezer and oven. That makes it common for bakery applications. It is broadly recyclable but carries the highest converted unit cost of the three substrates and adds meaningful weight to freight and logistics costs.

The right substrate is determined by your product's specific requirements.  Work through these questions:

1. What does the product need to survive? Temperature extremes (freezing, oven, microwave), moisture exposure, handling stress and shelf-life requirements are the first filters in any material decision.
2. How is the product processed? High-speed automation vs. manual packing, overwrap vs. sealed formats and fresh vs. frozen or MAP applications each drive different packaging requirements.
3. What does the end consumer expect? Modern shoppers prioritize sustainable, recyclable packaging that features a natural, non-plastic aesthetic while providing practical home performance, such as ease of handling, heating and disposal.
4. What are your regulatory and retailer requirements? Compliance with evolving regulations and retailer standards is critical, including state-level Extended Producer Responsibility (EPR) laws, plastic-reduction initiatives, recyclability requirements and material restrictions governing acceptable packaging formats.
5. What's the total cost of ownership? Converted unit cost is just the starting point. Line waste, rework, equipment compatibility and regulatory compliance costs all affect what a substrate actually costs your operation.

For many frozen, bakery, pizza, fresh protein and fresh produce applications, paperboard trays check every box while also supporting sustainability goals.

Key decision factors include:

• Product protection: moisture resistance, structural rigidity, barrier performance and temperature tolerance
• Processing compatibility: machine speed, denesters, sealing requirements and line integration
• Regulatory compliance: food contact safety, labeling requirements and regional plastic restrictions
• Sustainability profile: use of renewable materials, recyclability and credentials 
• Supply chain reliability: lead times, supplier location and inventory stability
• Cost: raw material price, tariffs and other logistics
• Brand presentation: color options, print-on-tray capabilities and material perception

The goal is finding the best fit for your specific combination of requirements and understanding where you're making trade-offs.

Paperboard

• Advantages: Renewable, widely recyclable, lightweight, dual-ovenable capable, consumer-preferred, printable and integrates cleanly into standard overwrap and sealing lines
• Disadvantages: Requires barrier coating for high-moisture applications and can be sensitive to humidity in storage

Foam

• Advantages: Low converted unit cost at scale, adequate moisture resistance and broad equipment compatibility on existing overwrap lines
• Disadvantages: Not ovenable, fossil-fuel derived and facing growing regulatory pressure and strongly negative consumer perception

Plastic

• Advantages: Oven-compatible, strong moisture resistance and rigid enough for frozen meal and entrée applications
• Disadvantages: Technically recyclable but rarely recycled in practice due to limited infrastructure; fossil-fuel-derived; facing increasing retailer sustainability scrutiny; and in frozen applications, can become brittle and prone to cracking, creating potential foreign material concerns. While some formats are microwaveable, performance can vary by material and design

Aluminum

• Advantages: Outstanding moisture and oxygen barrier performance, handles the full temperature range (freezer and oven) and broadly recyclable
• Disadvantages: Aluminum has the highest unit cost of the four substrates, is significantly heavier than paperboard and plastic, increasing freight costs, has limited printability compared to paperboard and is energy-intensive to produce. Most aluminum is not produced in the US, so supply chain issues can occur

For most food tray packaging use cases, paperboard is the stronger substrate choice across the criteria that matter most to brands and retailers.

Pressed paperboard packaging wins on:

• Sustainability and recyclability
• Consumer preference and brand perception
• Regulatory alignment (plastic restrictions are expanding in the US and globally)
• U.S. raw material availability (wood pulp, recycled fiber) vs. plastic's globally dispersed supply

Plastic has historically won on:

• Raw unit cost at high volumes
• Moisture resistance without barrier coatings
• Compatibility with legacy equipment

The gap for plastic’s advantages is narrowing. Engineered paperboard trays, like those manufactured by PaperTech, now deliver moisture resistance, dual-ovenable performance and machine compatibility that wasn't possible decades ago. For food brands evaluating a switch, the performance trade-offs are smaller than many expect, while the business and brand benefits are significant.

Pressed paperboard trays offer several meaningful advantages over plastic substrates for retail-ready food applications:

• Recyclability: Paperboard is accepted in curbside recycling programs across the US. Plastic foam trays and many plastic films are not.
• Consumer appeal: Nearly 80% of consumers say they are more likely to buy products packaged with paper.
• Regulatory positioning: Plastic restrictions and financial penalties are growing at the state level. Paperboard sidesteps that risk entirely.
• Printability: Due to its smooth surface, paperboard can be customized with color schemes, brand details, nutritional labels and QR codes.
• Domestic supply: US raw material availability (wood pulp and recycled fiber) provides a more stable supply chain with far less exposure to tariff volatility than foam and plastic substrates, which rely on more globally dispersed sourcing.
• Dual-oven capability: PaperTech's paperboard trays are engineered to perform from freezer to conventional or microwave oven — something most plastic trays cannot do.

• Durability: Aluminum and rigid plastic have historically been considered the durability benchmark. However, engineered paperboard, with structural integrity, optimized flange design and moisture-resistant coatings, can perform comparably in many food processing environments, including high-speed automated lines and applications involving freezing and heating.
• Cost: Foam and commodity plastics carry the lowest raw converted cost. Paperboard sits in the mid-range but often delivers a lower total cost when rework reduction, waste and regulatory compliance are factored in.
• Performance: Performance requirements vary by application. Dual-ovenable capability is critical for frozen food. Structural rigidity and moisture resistance are key performance requirements in fresh protein and produce applications. Structural rigidity through bake cycles matters for bakeries. PaperTech engineers trays specifically for each of these performance profiles.

Every substrate involves trade-offs. The most important ones for processors to understand:

• Cost vs. sustainability: Paperboard carries a higher converted unit cost than commodity foam at low volumes. Plastic sits in a similar cost range to paperboard but without the sustainability upside. It's technically recyclable but rarely recycled in practice. At scale, paperboard's cost gap versus both plastics narrows. When rework, waste and regulatory risk are factored in, paperboard often wins on total cost of ownership.
• Oven and temperature performance: Dual-ovenable paperboard and plastic are the two substrates that handle freezer-to-oven temperature cycling, making them the primary options for frozen meal and entrée applications. Foam is not ovenable. Aluminum handles the full temperature range but at a significantly higher unit cost. For processors who need ovenable performance without the cost or sustainability drawbacks of plastic, dual-ovenable paperboard is the most viable path.
• Moisture performance vs. recyclability: Foam and plastic resist moisture without barrier coatings, but at the cost of recyclability and consumer preference for sustainable products. Barrier-coated paperboard achieves strong moisture vapor transmission resistance while remaining recyclable and repulpable. Aluminum offers the best moisture and oxygen barrier of any substrate, but at a cost and weight premium.
• Domestic vs. imported supply: Offshore substrates may offer lower upfront pricing, but they often come with added risks: tariffs, longer lead times, quality variability and supply chain inconsistency. Domestic paperboard manufacturers like PaperTech provide a more reliable alternative, delivering consistent quality, stable supply and dependable lead times, making them a competitive and consistent option.
• New substrate vs. line compatibility: Converting to a new substrate sometimes requires equipment adjustments. PaperTech's engineering team works directly with processors to validate smooth integration into existing overwrap and sealing lines before full production commitment.

Several forces are converging to make plastic a less viable long-term substrate choice for food processors:

• Regulatory pressure: States, including California and Oregon, have passed or are advancing legislation restricting single-use plastics. Extended Producer Responsibility (EPR) programs are adding direct costs to plastic substrate use. While aluminum isn't currently targeted by plastic-specific legislation, it faces growing scrutiny under broader single-use packaging regulations in some markets.
• Retailer requirements: Major grocery chains like Walmart, Costco and Whole Foods have made public commitments to reduce plastic packaging. Processors who can't meet those substrate expectations risk losing shelf space.
• Consumer sentiment: Preference for sustainable packaging has shifted significantly and continues to move against foam. About 80% of consumers are more likely to buy products packaged with paper.
• Cost and weight pressure: As input costs rise and sustainability reporting becomes standard, the cost-per-tray and emissions-per-shipment of aluminum are drawing more scrutiny from procurement and sustainability teams alike.
• Tariff and supply chain exposure: Tariff volatility has made that exposure increasingly difficult to manage. Aluminum is similarly exposed, with a large share of US aluminum supply and finished goods tied to global commodity markets and overseas manufacturing.
• Brand strategy: More processors view paperboard as a competitive differentiator, not just a compliance checkbox. Paperboard's natural appearance, printability and sustainability credentials are increasingly seen as brand assets that plastic and aluminum cannot match.

• Product compatibility: Does the new substrate meet all performance requirements, including temperature range, moisture vapor transmission, structural integrity and seal surface quality?
• Equipment compatibility: Will your current overwrap, form-fill-seal or conveying equipment handle the new substrate? What modifications or tooling changes may be needed?
• Trial and validation: Budget time for lab testing and line trials before full production commitment.
• Supplier support: Choose a manufacturer with engineering resources who will work alongside your team through the conversion, not just ship product.
• Food contact compliance: Confirm the new substrate meets all applicable food contact safety and labeling requirements.
• Cost modeling: Compare the total cost of ownership, not just the converted unit cost. That includes waste, rework, shipping costs and regulatory fines.
• Timeline: Substrate conversions typically take weeks to a few months, depending on application complexity.

• Line disruption: New substrates can behave differently on existing equipment. Slide angle, stiffness, caliper and dimensional tolerances all impact performance on overwrap and sealing lines. Aluminum-to-paperboard or foam-to-paperboard conversions may require minor or major adjustments depending on the equipment. But with the right support and testing, there should be minimal disruptions to existing lines.
• Performance considerations: New substrates may not perform identically under all processing conditions. It’s important to validate key attributes early in the trial process — such as barrier performance, seal integrity and oven or temperature cycling — to ensure the right paperboard specification is selected for your application.
• Customer and retailer communication: If a substrate change impacts product appearance or shelf presentation, it’s important to align with retail partners in advance. Packaging transitions can be positioned proactively as a sustainability upgrade, helping maintain consumer confidence while supporting brand goals.
• Lead time exposure: Planning ahead is critical when transitioning to a new substrate. Lead times for raw material sourcing, production and any required custom tooling should be accounted for early to ensure a smooth and timely conversion.
• Requalification timelines: Packaging changes often require validation and testing across co-manufacturers, retailers and, in some cases, consumers. These steps can extend timelines, so it’s important to factor in testing, approval and requalification as part of the overall conversion plan.

Working with an experienced manufacturer like PaperTech, who has deep engineering support, on-site consultation capability and a track record of successful substrate switches, significantly reduces these risks.

PaperTech has guided many processors through this conversion. Our typical process:

1. Discovery: Evaluate your current tray specifications, line configuration, product requirements and sustainability goals with the PaperTech team. Key factors such as sealing requirements, equipment capabilities, production conditions and product expectations are assessed to determine fit and identify the optimal solution. On-site consultations can be scheduled as needed.
2. Sample development: With a portfolio of 150+ existing tray designs and full custom development capabilities, our engineering team can quickly identify a proven option or create a tailored solution. We develop drawings and mockups to ensure proper fit and functionality, working with you to select or design the right tray for your specific application.
3. Lab and line testing: Samples are evaluated for moisture resistance, structural integrity, seal surface quality, temperature tolerance and overall runability. Validation includes both lab testing and on-line trials to confirm equipment compatibility, throughput and line efficiency. Equipment adjustments are common during substrate transitions, and our engineering team supports and manages this process.
4. Optimization: Based on trial results, substrate specifications and equipment settings are refined to improve performance and consistency. This may include adjustments to caliper, coating or tray design, as well as sealing parameters, line speed and handling. The goal is to ensure optimal runability, product protection and efficiency on your production lines prior to full-scale launch.
5. Production ramp: Transition into full-scale production with continued hands-on support from PaperTech’s engineering and commercial teams. We work alongside your team to monitor initial runs, fine-tune performance and ensure consistency across production. Ongoing support includes troubleshooting, supply coordination and demand alignment to help ensure a smooth, stable and successful launch.

Most processors find the conversion smoother than expected, especially when working with a supplier who provides on-site engineering support throughout.

• Equipment friction: Paperboard trays may require guide adjustments, timing changes or updated vacuum settings on automated overwrap and sealing lines. Conversions from aluminum typically require more significant tooling and setup changes than conversions from foam or plastic, given the greater difference in substrate weight, stiffness and forming characteristics.
• Moisture and barrier performance expectations: Processing teams converting from aluminum, which offers an exceptionally high moisture and oxygen barrier, sometimes have the highest initial doubts about barrier-coated paperboard. Teams converting from foam often underestimate how effectively barrier-coated paperboard manages moisture vapor transmission. In both cases, skepticism is normal and typically resolved quickly during lab and line trials.
• Temperature performance validation: Processors converting from plastic, which is oven-compatible, need to validate that dual-ovenable paperboard meets their specific temperature cycling requirements. PaperTech's dual-ovenable trays are engineered for freezer-to-oven performance, but application-specific validation is always recommended.
• Supplier vetting: Not all paperboard tray manufacturers offer the same engineering depth or quality consistency, particularly for more complex conversions from aluminum or plastic. On-site consultation capability and quality control rigor matter significantly when the performance bar is high.
• Timeline pressure: Rushing a substrate conversion to meet a retailer's deadline increases risk across the board. This is especially true for aluminum conversions, which tend to have longer validation timelines. Engage your supplier earlier than you think you need to.

At the unit cost level, foam trays are often the lowest-cost option, but they lack recyclability and are increasingly out of step with consumer and retailer sustainability expectations. Plastic, paperboard and aluminum pricing can vary based on application, volume and specification.

Unit cost alone doesn’t reflect total packaging cost. Factors such as waste, rework, downtime, compliance and supply chain reliability all play a role, often making paperboard a competitive, and in some cases more cost-effective, solution.

What factors drive the cost of food packaging material (substrates)?

• Raw material inputs: Fiber, resin and aluminum prices fluctuate based on global market conditions and supply dynamics, directly impacting overall substrate costs.
• Converting and coating costs: Moisture resistance, printing and forming all contribute to converted unit cost. Processing requirements can vary by substrate, with some materials requiring more energy-intensive forming or additional processing steps depending on the application.
• Tariffs and trade policy: Substrates sourced from overseas — including plastic trays and aluminum components manufactured in Asia — are exposed to tariff changes. Domestic sourcing eliminates this risk entirely.
• Volume: Converted unit cost decreases with higher volume across all substrates.
• Customization: Custom shapes, sizes, print and barrier coating specifications add cost compared to standard offerings across all substrate types.
• Logistics: Substrate weight, cube efficiency and shipping distance all affect total landed cost. Aluminum's weight premium adds meaningful freight cost relative to paperboard.

Substrate pricing varies based on market conditions, application and specification. Foam is typically the lowest-cost option, but it is not suitable for dual-ovenable applications and requires alternative materials based on performance needs. The total cost picture for processors is more nuanced across all three:

• Rework and line waste: PaperTech's trays are engineered for high-speed processing lines and designed to minimize cracks, dents and rejects — reducing costly rework and downtime that affect foam, plastic and aluminum converters.
• Regulatory costs: As plastic substrate restrictions expand, compliance costs for processors using foam and plastic are rising. Additionally, aluminum faces growing scrutiny under broader single-use packaging regulations in some markets.
• Freight and weight: Aluminum's weight premium generates meaningful freight cost across the supply chain. Paperboard's lighter weight and superior nesting ratio — paperboard trays nest 250% more efficiently than foam — reduce both freight cost and storage space requirements.
• Retail access and brand value: Sustainable paperboard packaging supports premium positioning and retailer access that foam, plastic and aluminum increasingly cannot match on sustainability scorecards.
• Supply chain risk: Offshore plastic and aluminum substrates carry tariff and lead-time exposure that domestically sourced paperboard does not.

Many PaperTech customers find that when they model the total cost of ownership, not just the converted unit cost, pressed paperboard trays outperform expectations against all three substrates.

Significantly. And this has become one of the most urgent drivers of substrate conversion among processors in recent years. Those relying on plastic trays or aluminum components manufactured overseas have faced tariff-driven cost spikes that are difficult to pass through quickly, extended ocean freight lead times requiring larger safety stock, quality inconsistency that's difficult to manage remotely and sudden supply gaps when overseas converting capacity tightens. Aluminum is particularly exposed to global commodity price swings and tariff changes on imported metal.

PaperTech manufactures 100% of its pressed paperboard trays domestically from our 150,000 sq. ft. facility in Ohio. Processors who convert to PaperTech eliminate tariff exposure entirely and gain a responsive domestic supplier with predictable lead times, consistent quality and a 98% On-Time and Complete rate.

• Right-size your substrate: Unnecessary caliper or coating adds converted cost across all substrates. Engineering trays to the minimum required spec reduces both cost and material waste.
• Optimize line performance: Substrates that run cleanly with minimal rejects and rework reduce the true total cost of ownership, a meaningful advantage paperboard holds over both foam and aluminum on most processing lines.
• Factor in freight weight: Aluminum's weight premium is often overlooked in initial cost comparisons. Paperboard's lighter weight and superior nesting ratio significantly reduce freight costs and storage requirements.
• Source domestically: Domestic manufacturers eliminate tariff risks and reduce safety stock requirements for both plastic and aluminum substrate alternatives.
• Plan conversions carefully: Rushed substrate conversions cost more in trials, downtime and rework than well-planned ones.

Substrate selection is a direct production input, not a downstream consideration. Substrates that are dimensionally consistent, mechanically predictable and engineered for your specific line configuration run cleaner, faster and with less waste — whether you're currently running foam, plastic or aluminum.

Substrates that cause frequent jams, rejects or slowdowns on overwrap or sealing equipment destroy throughput efficiency. PaperTech trays are engineered with rigidity and consistent processing line performance as core design requirements. Our engineering team validates line integration before full production commitment — often through on-site visits — to identify and address potential challenges early, so processors aren’t discovering issues after conversion.

Yes. PaperTech's pressed paperboard trays are engineered for compatibility with standard automated overwrap and sealing equipment used across food processing applications. Key substrate design factors — stiffness, caliper, dimensional tolerances and coefficient of friction — are all evaluated for machine performance on standard processing lines.

However, every line is different, and every incumbent substrate creates different starting conditions. Processors converting from foam typically require only minor settings adjustments. Those converting from plastic or aluminum may require more significant tooling or setup changes given the greater differences in substrate weight, stiffness and forming characteristics. PaperTech's engineering team reviews line specifications and provides guidance on any adjustments needed for seamless integration.

The scope of operational change depends on which substrate you're converting from. Common adjustments across all three:

• Equipment settings: Overwrap speed, vacuum levels, guide spacing and timing may need adjustment to suit paperboard's stiffness and caliper. Foam conversions typically require the least adjustment. Plastic conversions are moderate. Aluminum conversions typically require the most significant tooling and setup changes given aluminum's greater weight, rigidity and forming differences.
• Handling practices: Paperboard responds differently to handling than foam, plastic and aluminum. Brief line staff training on proper substrate handling and stacking practices helps regardless of which substrate you're moving away from.
• Storage conditions: Paperboard substrates should be stored in climate-controlled environments away from excessive humidity to maintain dimensional stability and barrier performance. This is a meaningfully different storage requirement than aluminum or rigid plastic. Processors should update their receiving and storage protocols accordingly. PaperTech can advise on best practices for your facility.
• Quality inspection: QC criteria and inspection points should be updated to reflect paperboard's performance characteristics. Processors converting from aluminum should pay close attention to updating barrier performance and seal surface inspection criteria.

PaperTech provides hands-on engineering support during line trials and through the full conversion to minimize production disruption, whether you're converting from foam, plastic or aluminum.

• Handling: Structural rigidity and caliper determine how trays behave on conveyors, in stacking and during hand-packing operations. PaperTech trays are designed for structural integrity throughout the full supply chain, comparable to plastic and aluminum in rigidity for most food tray applications and significantly more rigid than foam under distribution loads.
• Storage: Paperboard substrates can be sensitive to humidity. Controlled temperature and humidity storage conditions protect dimensional stability and barrier coating performance. Foam and aluminum are less sensitive to storage humidity. Processors converting to paperboard from either substrate should update their storage and receiving protocols. PaperTech can advise on best practices for your facility.
• Transportation: Lighter-weight substrates reduce freight cost. Paperboard trays nest 250% more efficiently than foam, are significantly lighter than aluminum and are comparable in weight to plastic, delivering meaningful reductions in freight cost and storage cube requirements across the supply chain.
• Retail presentation: Trays must arrive at the retail shelf without cosmetic damage after freezing, thawing and ambient distribution. PaperTech's structural engineering addresses requirements across handling, storage and transportation requirements.

Yes. PaperTech is a US-based manufacturer of pressed paperboard trays, operating from a 150,000 sq. ft. production facility in Ohio. PaperTech supplies American-made sustainable paperboard trays to food processors across frozen food, fresh protein, fresh produce, bakery and pizza applications — with a 98% On-Time and Complete rate.

Domestic paperboard manufacturing is well-established and fully capable of serving national food brands at scale. For processors currently sourcing foam, plastic or aluminum trays from overseas suppliers, switching to a domestic paperboard manufacturer like PaperTech eliminates tariff exposure and delivers meaningful improvements in lead time reliability, quality consistency and supplier responsiveness.

Several factors are accelerating the shift to domestic sourcing among food processors across paperboard, foam, plastic and aluminum substrate categories:

• Tariff risk: Packaging manufactured overseas, including plastic trays and aluminum components sourced from Asia, is exposed to tariff changes that can significantly increase landed cost with little advance warning.
• Lead times: Offshore lead times are long and unpredictable. Domestic manufacturers respond faster to demand changes, replenishment needs and spec adjustments across all substrate types.
• Quality control: It's far easier to maintain consistent substrate quality standards with a domestic manufacturer you can visit, audit and engage directly, regardless of whether you're sourcing paperboard, foam, plastic or aluminum trays.
• Supply chain resilience: The disruptions of recent years have elevated supply chain reliability to a board-level priority for processors. Domestic sourcing significantly reduces exposure across all substrate categories.
• Responsiveness: When a line issue arises or demand needs to scale quickly, a domestic supplier is far easier to reach and respond effectively than an overseas manufacturer operating across time zones and language barriers.

Evaluate suppliers across these dimensions, whether you're sourcing paperboard, foam, plastic or aluminum trays:

• Technical capability: Can they engineer a high-performing tray that meets your specific product and line performance requirements?
• Quality systems: What quality control and food contact compliance processes do they have in place?
• Manufacturing location: Are they domestic or offshore? Consider the full supply chain and tariff implications of each.
• Engineering support: Will they work alongside your processing team through line trials and substrate conversion, or just ship product?
• On-time performance: What is their documented on-time and complete delivery rate? PaperTech maintains a 98% On-Time and Complete rate.
• Financial stability: Is this a supplier you can build a long-term sourcing relationship with?
• Customization capability: Can they accommodate your tray size and shape, barrier coatings and branding requirements (color and print-on tray capability)?

Beyond basic converting capability, the best paperboard tray manufacturers bring genuine substrate engineering expertise to your application rather than just a product catalog. They're proactive and anticipate your processing needs rather than reacting to problems.

They have a documented track record of successful substrate conversions — from foam, plastic and aluminum — in your product category, transparent communication on lead times and the production capacity to scale with your demand.

Key differentiators for PaperTech include over 25 years of paperboard proficiency, an internal engineering department and a customer-trusted consultative commercial team. Our on-site support and rigorous quality control — evidenced by a DPPM below 1% — consistently set us apart.

Substrate selection is your product's first line of defense from the moment it leaves your processing facility to the moment a consumer opens it. The substrate effects:

• Physical protection: Structural rigidity and caliper prevent crushing and deformation during high-speed line handling and distribution. Engineered paperboard is comparable to plastic and aluminum in rigidity for most food tray applications.
• Moisture management: Barrier-coated paperboard performs comparably to plastic in most fresh and frozen environments, and approaches aluminum performance in many applications with the right coating specification.
• Temperature performance: For frozen and dual-ovenable applications, the substrate must perform through extreme temperature cycling without warping, cracking or coating delamination. Dual-ovenable paperboard and aluminum are the two substrates that reliably handle freezer-to-oven performance. Foam and plastic do not perform reliably through full oven cycles.
• Seal surface integrity: For overwrapped or lidded trays, the substrate must maintain a clean, consistent seal surface throughout its processing and distribution lifecycle. This is a requirement paperboard, foam and p and aluminum all meet when properly specified.

PaperTech engineers every tray to meet the specific protection requirements of its application — frozen food, fresh protein, produce, bakery or pizza — rather than applying a one-size-fits-all substrate approach.

For food tray applications, the right substrate depends on the specific performance requirement:

• Structural strength: Engineered paperboard with reinforced flanges and formed geometry provides excellent structural rigidity across most food tray applications — comparable to foam, plastic and aluminum under distribution loads.
• Moisture vapor transmission resistance: Barrier-coated paperboard, aluminum and plastic all offer strong moisture resistance. Aluminum provides the highest absolute barrier performance. Barrier-coated paperboard meets the moisture requirements of the vast majority of fresh and frozen food applications. PaperTech's barrier-coated trays are specifically engineered for the moisture demands of fresh and frozen food environments.
• Temperature extremes: Aluminum and dual-ovenable paperboard both perform reliably through freezer-to-oven cycles. Foam is not ovenable. Standard plastic handles oven temperatures but is generally not recommended for microwave use and does not match dual-ovenable paperboard's combined freezer-oven-microwave range.

For most fresh protein, fresh produce, frozen, bakery and pizza food processing applications, PaperTech's paperboard trays deliver the right combination of structural performance, moisture vapor transmission resistance and temperature tolerance.

Poorly specified or engineered substrates degrade product quality throughout the supply chain, regardless of whether you're running foam, plastic or aluminum:

• Inadequate moisture vapor transmission resistance: Causes texture changes, spoilage or ice crystal formation in frozen products. That’s a risk with foam in high-moisture environments and with underspecified paperboard barrier coatings.
• Structural failure: Under processing or distribution loads results in deformed and unsaleable product. This is the most common failure mode for foam under distribution stress.
• Seal surface failure: In overwrapped or lidded trays compromises freshness and creates food safety exposure. This is a risk across all substrate types when seal surface specs are not maintained.
• Temperature performance failures: Such as warping or delaminating in the oven, generate consumer complaints and costly returns. This is a known risk with foam (which cannot go in the oven) and with plastic at microwave temperatures.

PaperTech trays are validated for performance through the full application lifecycle — from high-speed processing lines through hard freezing, distribution, retail display and end-use. That helps ensure product quality is protected at every step.

Extended Producer Responsibility (EPR) is a policy framework that shifts the cost of collecting, sorting and recycling packaging from municipalities to the brands and processors that produce packaged goods. Under EPR, companies pay fees to a producer responsibility organization (PRO) based on the type and volume of packaging they place on the market.

EPR for packaging is already law in California, Colorado, Oregon and Maine, with additional states advancing similar legislation. Most programs take effect between 2025 and 2030.

For food processors, substrate choice is now a direct EPR cost variable:

• Foam carries the highest fee exposure, with no viable recycling pathway in most markets and is being banned outright in some state programs
• Plastic faces moderate-to-high fees due to low real-world recovery rates, despite being technically recyclable
• Aluminum generally falls in the moderate range, given a strong recycling infrastructure, but high production energy intensity
• Paperboard typically has the lowest EPR tax per-pound fee exposure because it is widely accepted in curbside recycling programs and has high actual recovery rates, both of which EPR programs reward

The most commercially mature and widely adopted sustainable alternatives to foam and plastic food trays are:

• Paperboard trays: The leading sustainable substrate for fresh protein, frozen, fresh produce and bakery tray applications at commercial processing scale
• Molded fiber: Used in produce (clamshells) and foodservice
• Aluminum trays: Recyclable and temperature-versatile, though energy-intensive to produce

For food tray applications at a commercial processing scale, paperboard is the most proven, accessible and cost-competitive sustainable substrate.

Paperboard has a meaningfully better environmental profile than foam and plastic, and a favorable profile versus aluminum across several key dimensions:

• Recyclability: Paperboard is widely accepted in curbside recycling programs across the US. Plastic is technically recyclable, but rarely recycled in practice due to limited consumer-accessible infrastructure. Aluminum has strong recycling recovery rates but it depends on consumer participation in metal recycling programs. Plus, its high production energy intensity offsets some of that end-of-life advantage in lifecycle analyses.
• Renewable feedstock: Paperboard is produced from wood fiber, which is a renewable raw material. Foam and plastic are both derived from fossil fuels. Aluminum requires significant energy input and mining of bauxite ore.
• Consumer recycling behavior: Paperboard is more likely to actually be recycled by consumers because curbside paper recycling infrastructure is far more accessible than plastic or aluminum recycling in most US markets.

A full lifecycle analysis will depend on the specific substrates, geographies and end-of-life scenarios being compared, but for most food processing tray applications, paperboard compares favorably against foam, plastic and aluminum.

Yes. Our pressed paperboard trays are manufactured with raw materials from certified sustainable forestry sources (Sustainable Forestry Initiative and Forest Stewardship Council), making them recyclable and compliant with packaging regulations. While all our trays are recyclable, check local guidelines for recycling in your area. Learn more about the sustainability of our pressed paperboard trays here.