As Australia’s packaging regulations evolve, more brands are rethinking their sustainable meal tray design. The shift to recyclable or compostable materials isn’t just a regulatory checkbox — it’s a brand evolution. The challenge for many? Finding a sustainable alternative that performs just as well as their current tray design without affecting sealing, heat tolerance, or shelf appeal.
That’s where material science meets design intelligence. With the right approach, it’s entirely possible to replace legacy plastics with eco-compliant materials that maintain your product’s quality, presentation, and protection.
Why Change is Now Essential
Australia’s 2025 packaging reform has made one thing clear — non-recyclable or multi-layer plastics will no longer pass compliance. The DCCEEW (Department of Climate Change, Energy, the Environment and Water) is enforcing EPR (Extended Producer Responsibility), meaning businesses must ensure their packaging is recoverable, recyclable, or compostable.
Meal trays made from PVC, PS, or laminated plastics are on the phase-out list. That puts food manufacturers and meal delivery brands in a position where redesigning is no longer optional — but it doesn’t mean you have to lose the features your customers love.
What Makes a Tray Truly Sustainable
A sustainable meal tray design isn’t just about using less plastic. It’s about choosing materials that are recyclable within Australian systems, verified under PREP (Packaging Recyclability Evaluation Portal), and accurately labeled using the ARL (Australasian Recycling Label).
The ideal modern tray design combines:
- Mono-material structures for recyclability efficiency
- CPET or rPET bases for temperature resistance and clarity
- Compostable or recyclable lids compatible with sealing systems
- Reduced material weight for a lower carbon footprint
These attributes ensure your tray performs through the product’s life cycle while qualifying for Australia’s upcoming compliance standards.
How Carewell Delivers Smart, Sustainable Tray Replacements
At Carewell Group, we help businesses transition from legacy packaging to sustainable meal tray design with zero compromise on quality or brand consistency.
Through our Custom Solutions service, our packaging engineers replicate your existing tray’s exact dimensions, compartment layout, and sealing compatibility — but with recyclable, food-safe materials.
Our Sustainability program ensures that every design meets ARL verification standards and PREP recyclability grading, preparing your brand for the 2025 mandates.
We also provide full lifecycle testing to confirm that your redesigned tray holds up to:
- Freezer and microwave use
- Heat sealing and film compatibility
- Product integrity during distribution
- Compliance across Australian recycling streams
Real-World Example: From Plastic to Recyclable CPET
One of our clients — a major food manufacturer — needed to replace their black PS meal tray. We developed a CPET-based version that maintained:
- The same look, compartment structure, and durability
- Recyclability through curbside systems
- Compliance under the Australian Recycling Label (ARL)
The result was a smooth transition that reduced costs over time and kept their brand identity intact while meeting all upcoming regulations.
Why Choose Carewell for Your Redesign
We’re not just a packaging supplier — we’re your compliance partner. From evaluating your existing materials to modeling the environmental and financial impact of each alternative, we make sustainability a measurable upgrade, not a risk.
Whether you’re working with thermoformed trays, CPET food containers, or hybrid packaging, our solutions ensure your products remain practical, presentable, and compliant.
You can explore our durable, recyclable CPET Trays — already tested for EPR readiness and certified recyclable under Australian standards.
The Bottom Line
Moving toward a sustainable meal tray design isn’t about replacing what works — it’s about improving what’s possible. With the right technical insight and design alignment, you can achieve the same performance and brand look while reducing environmental impact and regulatory risk.
Carewell helps you future-proof your packaging — keeping your meals protected, your brand consistent, and your materials compliant.
Location: Carewell Group Pty Ltd, Unit 27/191 McCredie Road, Smithfield, NSW 2164
Phone: +61 0477 123 699
Email: sales@carewellgroup.com.au | info@carewellgroup.com.au | logistics@carewellgroup.com.au
