In the ever-evolving world of food packaging, few materials have proven as adaptable and reliable as PP trays. Short for Polypropylene, PP is the unsung hero of packaging design — balancing strength, safety, heat tolerance, and recyclability. From takeaway meals to bulk logistics trays, PP has become the go-to material for businesses seeking performance and compliance without unnecessary cost.
Let’s unpack why PP trays are the quiet powerhouse behind so many successful packaging lines and how they’re helping Australian brands stay future-ready under tightening sustainability regulations.
What Makes PP Trays So Popular
PP (Polypropylene) is a lightweight, flexible polymer known for its durability and versatility. It’s used across industries, but its biggest impact has been in the food and beverage sector — particularly in applications where moisture resistance, temperature stability, and food safety are essential.
The material’s unique characteristics make PP trays suitable for:
- Fresh and frozen meals
- Bakery and confectionery packaging
- Takeaway and delivery containers
- Industrial and logistics packaging applications
PP is tough enough for transit, gentle enough for sealing, and approved for direct food contact — all while being fully recyclable under Australia’s 5 PP recycling stream.
Key Advantages of PP Trays
- High Heat Resistance
PP trays perform well in microwave and dishwasher conditions, tolerating temperatures up to 120°C without deformation. That makes them ideal for reheatable meal packaging and commercial foodservice operations. - Lightweight and Impact Resistant
Compared to glass or aluminium, PP trays are much lighter, cutting transport costs and reducing carbon footprint. They’re also less prone to cracking or denting, improving product safety and presentation. - Moisture and Chemical Resistant
PP naturally resists moisture, oils, and acids — perfect for packaging sauces, curries, and other liquid-heavy foods without leakage or contamination. - Recyclable and Sustainable
Under Australia’s National Packaging Targets 2025, PP trays are classified as recyclable and widely accepted in local recycling streams. Businesses choosing PP reduce landfill waste while staying compliant with EPR (Extended Producer Responsibility) regulations. - Customisable for Every Industry
PP can be easily moulded into any shape, thickness, or compartment layout — from single-serve trays to multi-compartment meal packs. This flexibility allows brands to maintain design identity while using eco-friendly materials.
PP Trays vs. Other Packaging Materials
When compared to PET, CPET, or Bagasse, PP trays stand out for cost efficiency and versatility:
| Feature | PP Trays | CPET Trays | Bagasse Trays |
|---|---|---|---|
| Microwave Safe | Yes | Yes | Limited |
| Oven Safe | No | Yes | Moderate |
| Recyclable | Widely | Widely | Compostable |
| Lightweight | Very | Moderate | Moderate |
| Custom Shapes | Excellent | Good | Limited |
For food brands that don’t require oven compatibility, PP trays offer the best overall value — delivering flexibility, durability, and compliance at a lower cost point.
How PP Trays Support Sustainability Goals
Australia’s packaging reform is changing how companies think about materials. With EPR compliance and ARL labelling now on the horizon, every packaging decision has both environmental and financial consequences.
PP trays give brands a low-barrier entry into sustainable packaging design:
- Fully recyclable and supported by most municipal waste streams
- Compatible with clear labelling for ARL and PREP verification
- Available in rPP (recycled polypropylene) options for circular economy compliance
By adopting recyclable PP now, businesses can avoid costly redesigns later and reduce exposure to eco-modulated fees once mandatory compliance begins.
You can learn more about Carewell’s eco initiatives on our Sustainability page.
The Carewell Group Advantage: Custom PP Tray Solutions
At Carewell Group, we specialise in creating tailored PP tray packaging for Australia’s food, retail, and industrial sectors. Whether you’re replacing banned plastics or upgrading to recyclable alternatives, our material engineers guide you through the entire process.
Our Custom Solutions service allows you to:
- Replicate existing packaging design in compliant, recyclable PP
- Maintain current dimensions, strength, and clarity
- Achieve PREP and ARL certification for EPR compliance
- Optimise production efficiency and sealing performance
We also offer a range of ready-to-use food trays and packaging products designed to meet HACCP and food-grade safety standards.
Use Case: A Smarter Switch
A leading meal prep company recently partnered with Carewell Group to replace its mixed-material trays with 100% recyclable rPP trays. The result?
- 22% reduction in packaging weight
- Simplified recycling for end consumers
- Zero impact on food freshness or sealing performance
This shift not only reduced compliance risks but also boosted their brand reputation as an eco-conscious supplier.
Final Thoughts
In an era where packaging performance and sustainability must go hand in hand, PP trays are the pragmatic choice. They deliver everything modern businesses need — strength, adaptability, recyclability, and compliance — without compromising on appearance or function.
If your packaging still relies on outdated plastics or non-recyclable formats, it’s time to modernise before the next wave of EPR reforms hits.
Reach out to Carewell Group to explore how PP trays can future-proof your packaging.
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
