How Frozen Food Processors Are Switching to Paper Trays Without Disrupting Existing Production

A frozen food brand encountered a roadblock trying to secure a coveted placement for their Mexican bowl in a popular nationwide retailer: the product was packaged in a plastic tray. 

Switching to a more sustainable packaging like pressed paperboard might seem like a complex transition. However, the frozen food brand worked with PaperTech, who used a consultative approach to their color and film, and created a pressed paperboard tray that landed them that spot in the popular retailer. 

Most importantly, the paper trays fit seamlessly into their existing production line. By integrating dual-ovenable paper trays into their processing lines, they turned a potential setback into expanded market reach and sales that surpassed expectations.

Here’s what their success can teach you.

What’s the cost of inefficient frozen food packaging?

When packaging fails to perform on the production line, whether due to jamming, misfeeds or other disruptions, the consequences are immediate and costly:

• 15–25% reduction in output per hour when lines are stopped or slowed
• $30,000–$50,000 in losses per incident of downtime
• 74% of consumers link poor packaging to lower product quality

For frozen food processors considering a switch to sustainable packaging, the cost of inefficiency may cause hesitation. The good news is that durable pressed paperboard trays can be engineered to withstand the rigors of processing lines without compromising performance. 

How do sustainable paper trays perform in high-speed production lines?

Backed by over 25 years of engineering expertise, PaperTech pressed paperboard trays are designed to handle the same demanding conditions, while offering added advantages:

• Durable for automated lines: Strong enough for denesting, filling, sealing and stacking at high speeds
• Moisture-resistance and barrier-coating: Prevents cracking, warping or deformation in cold or humid environments
• Reinforced pressed paperboard: Reduces breakage and inconsistency by up to 60% compared to EPS or thin plastic trays

These features mean processors don’t have to sacrifice line performance for sustainability.

Can paper trays protect food during freezing, shipping and storage?

Packaging isn’t just about making it through the line. It’s about protecting the product until it reaches the shopper. PaperTech paper trays are designed to handle the rigors of the entire frozen food journey:

• Reinforced flanges for secure film sealing, ensuring strong seals that hold through freezing, shipping and heating
• Reliable structural strength that prevents cracking under stacking or distribution pressure
• Barrier protection that helps preserve freshness and reduce freezer burn

For consumers, secure seals and strong trays translate to confidence in the product. With 74% of shoppers judging quality based on packaging, that trust directly impacts repeat sales.

How do print-on-tray capabilities make frozen food processing more efficient and cost-saving? 

Packaging plays a central role in brand identity, and dual-ovenable pressed paper trays can increase efficiency and branding opportunities of frozen food products. With PaperTech’s print-on-tray capabilities, frozen food processors can take advantage of:

• Direct print capabilities: Brand logos, nutrition information, QR codes and promotional messages can be printed directly on the tray
• Fewer packaging steps: Eliminate the need for separate labels or sleeves, simplifying the production process
• Premium appearance: The natural look of paperboard creates a package that looks and feels sustainable

For processors, print-on-tray capability isn’t just about aesthetics. By removing labeling steps, in-line efficiency improves, while material and labor costs could be reduced.

How does having a domestic supplier help with simplifying your production’s switch to pressed paperboard? 

Relying on overseas plastics or imported trays leaves processors vulnerable to shipping delays, customs holds and raw material volatility. However, when packaging is sourced closer to home, processors gain confidence that their production lines won’t be slowed by supply issues.

A domestic paper tray supplier brings critical advantages to frozen food processors:

• Faster response times to any challenges or questions
• Reduced risk of disruption from global supply chain issues
• Closer collaboration on tray design, printing, and performance testing
• Support for American manufacturing and jobs

Thinking about making the switch to paper?

If you want to learn more about the trends impacting the frozen food market and what you can do to prepare proactively, here’s an educational resource: A Guide to Sustainable Paper Trays for Frozen Foods.

Transitioning to paper trays is more than a packaging change. It’s a business move. Our team specializes in helping frozen food brands transition smoothly and confidently. Reach out today and we’ll connect with you quickly to answer your questions.