The pressure to shift toward compliant packaging material is growing fast. With Australia’s EPR-driven packaging regulations approaching, brands that rely on traditional multi-compartment trays — especially in the food service and ready-meal sectors — are facing a hard question: how do you replicate complex designs without losing performance or shelf appeal?
The answer lies in re-engineering, not replacing. It’s entirely possible to reproduce your 5-compartment tray in sustainable, fully compliant materials that meet both functional and regulatory demands.
Why the 5-Compartment Tray Needs a Rethink
Multi-compartment trays are designed for precision — they separate sauces, proteins, and sides, maintain temperature, and protect the meal’s structure during transit. But traditional plastics like PVC or PS, which were once standard for these trays, are now under scrutiny. They’re classified as hard-to-recycle under the new Australian Packaging Regulation, meaning they’ll attract higher fees and possible design rejections under EPR compliance.
Yet that doesn’t mean your tray design must change — just the material science behind it.
Smart Substitutes That Match Your Existing Performance
At Carewell Group, we specialize in redesigning packaging that maintains your exact specifications — from tray size to compartment layout — while upgrading the material composition. Our team of engineers uses advanced material mapping and barrier analysis to identify alternatives that meet your product’s needs and future-proof it for compliance.
A few proven options include:
- CPET (Crystallized Polyethylene Terephthalate) – Recyclable, oven-safe, and ideal for heat-sealed meal trays.
- rPET (Recycled PET) – Perfect for cold food applications and clear visibility.
- Compostable Hybrids – Bio-based polymers suitable for short shelf-life or takeaway formats.
Our CPET Trays already meet ARL and PREP recyclability standards, proving that sustainability doesn’t require compromising on functionality.
Case Insight: A 5-Compartment Success Story
One of our food manufacturing clients faced the same challenge — a popular 5-compartment ready-meal tray that was non-recyclable under new standards. We recreated it using CPET with identical dimensions, compartment depth, and clarity. The result?
- Full recyclability under Australian guidelines
- Maintained sealing integrity and shelf presentation
- Reduced packaging weight by 12%
- Future compliance with upcoming DCCEEW design grading
This transformation turned a compliance concern into a long-term brand asset.
How Carewell Simplifies the Transition
Our Custom Solutions process makes material migration seamless:
- Audit & Analysis – We assess your current tray composition and recyclability score using PREP tools.
- Material Mapping – Identify the most suitable compliant material based on temperature tolerance, food safety, and lifecycle impact.
- Prototype & Testing – We replicate your tray’s exact form and test for heat resistance, sealing, and durability.
- ARL Verification – Ensure your new tray qualifies for the correct recycling label.
You get packaging that looks and performs the same — just built for a smarter, circular economy.
The Cost Advantage of Getting It Right Early
EPR compliance isn’t just about avoiding penalties — it’s about saving money. Under eco-modulated fee structures, brands using recyclable or reusable materials will pay significantly less in levies than those relying on hard-to-recycle plastics. That makes transitioning your 5-compartment tray an investment, not an expense.
Where to Start
If you’re currently using non-compliant or mixed-material trays, now is the time to act. The Sustainability team at Carewell can assess your packaging within days and provide a cost model that shows your savings under the new EPR framework.
We’ll help you stay ahead of regulation — and ahead of competitors who wait too long.
Final Thought
Sustainability doesn’t have to mean redesigning your entire packaging identity. With the right expertise, you can reproduce your 5-compartment tray exactly as it is — just cleaner, smarter, and compliant. The brands that make this shift now will lead in 2025 and beyond.
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
