When Perth-based Mini Dins approached Carewell Group, they had one clear mission — to find a 5-compartment meal tray design that met the needs of modern families, aligned with sustainability goals, and complied with local packaging regulations. The challenge? Replace a banned plastic design with an eco-friendly solution that didn’t compromise function, appearance, or cost.
What unfolded was a collaboration that blended innovation, material science, and thoughtful design — resulting in a tray that’s as practical as it is planet-friendly.
The Brief: Function Meets Sustainability
Mini Dins needed a meal tray that could handle multiple food types without mixing flavors, withstand reheating, and remain safe for children. On top of that, the packaging had to reflect their commitment to sustainability.
They were also facing the national packaging reform shift, with new rules phasing out non-recyclable plastics. This made the search for an approved, compostable or recyclable tray material not just an option — but a necessity.
The project began with a clear goal: create a 5-compartment meal tray that ticks all boxes — durability, safety, and sustainability.
Design Considerations: More Than Just Compartments
A well-designed tray isn’t about aesthetics alone — it’s about how it supports the customer experience and operational efficiency.
For Mini Dins, Carewell Group designed the compartments to serve specific purposes:
- Central section for main meals (curries, pastas, or proteins).
- Smaller compartments for sides, fruits, and snacks.
- One sealed section for sauces or dips.
This thoughtful separation ensures food remains fresh and visually appealing — even after transport or storage.
The design also supports portion control, an important element for Mini Dins’ family and school-focused meal programs.
Material Selection: Sugarcane Bagasse for an Eco Edge
After assessing options like CPET, PP, and aluminium, the Carewell team recommended sugarcane bagasse — a renewable by-product of the sugar industry.
Why it worked perfectly:
- Compostable and biodegradable, reducing landfill impact.
- Heat-resistant and grease-proof, ideal for hot meals.
- Microwave and oven safe, adding convenience for end users.
- Compliant with WA and national packaging standards.
This choice aligned with Mini Dins’ environmental ethos and gave their packaging a natural, premium look — something their customers immediately appreciated.
Explore more about our sustainable compartment trays and how they can elevate your brand.
The Prototyping Process
Creating the perfect 5-compartment tray required precision and testing. Carewell Group’s custom manufacturing team developed prototypes to assess:
- Portion accuracy
- Seal integrity with compatible film lids
- Stackability for storage and transport
- Material performance under heat and cold conditions
Feedback from Mini Dins’ chefs and logistics team was integrated into the final mold design — ensuring that the tray performed well from kitchen prep to delivery.
The collaboration highlighted Carewell Group’s strength in custom food packaging design, turning concept sketches into compliant, high-performing solutions.
Production and Compliance
Once finalized, the tray design was moved to scalable production, adhering to Australian quality and food safety regulations. The eco-friendly 5-compartment tray met WA sustainability guidelines and aligned with Mini Dins’ goal of full compliance under upcoming national packaging reforms.
Each tray batch was tested for:
- Structural strength
- Leak prevention
- Consistent compartment sizing
- Food contact safety
Carewell Group’s internal quality systems ensured that every tray leaving the facility met the same high standard that Mini Dins promised its customers.
Results: Efficiency, Sustainability, and Brand Uplift
The impact was immediate. Mini Dins now had a custom eco-friendly tray that:
- Enhanced presentation and portion control
- Improved storage and transport efficiency
- Aligned with eco-certification and compliance standards
- Strengthened their brand identity as a sustainable meal service
Customers noticed the change too — reporting that meals felt fresher, more balanced, and more premium.
Lessons Learned from the Collaboration
Mini Dins’ case underscores a growing truth in the packaging industry — innovation and sustainability are no longer separate goals.
By choosing the right packaging partner and focusing on materials like sugarcane bagasse, businesses can meet both environmental obligations and customer expectations without compromise.
For food brands across Australia, this collaboration demonstrates how sustainable design can elevate brand reputation while supporting real-world usability.
The Carewell Advantage
At Carewell Group, we specialize in creating custom sustainable packaging solutions that help businesses like Mini Dins thrive. From concept to compliance, our team ensures every detail serves your brand’s operational, environmental, and customer goals.
Explore more of our eco-friendly packaging solutions and learn how to future-proof your products with smarter, sustainable design.
Final Thought
The Mini Dins partnership is a glimpse of where the food packaging industry is heading — practical innovation that respects both people and the planet.
If you’re seeking to replace outdated plastic trays or design a custom sustainable meal tray, Carewell Group can help you turn that vision into a tangible, compliant product ready for today’s evolving market.
Carewell Group Pty Ltd
Unit 27/191 McCredie Road, Smithfield, NSW 2164
+61 0477 123 699
sales@carewellgroup.com.au | info@carewellgroup.com.au | logistics@carewellgroup.com.au
