Paper Shape Trays

Paper Shape trays are produced directly in-line on the Paper Shape Line 2, an automated tray forming system developed in collaboration with Cartotecnica Moreschini. The line starts with flat, die-cut cardboard blanks and converts them into rigid, ready-to-pack paper trays that are suitable for a wide range of food applications.

How the trays are made
The forming process is designed for repeatability and consistent tray quality across production runs:

• Flat, die-cut cardboard blanks with pre-creased, sealable lips are fed into the forming station.
• A mould and counter-mould system shapes each blank into a rigid tray with stable geometry.
• Trays exit forming with a fully flat base for improved stability and clean presentation.
• Finished trays are prepared for use with sealing operations, either immediately in-line or via stacking and transfer (depending on line setup).

Strength, stability, and efficiency
The tray design has been engineered to deliver practical performance on packing lines, not just sustainability credentials.

• Co-patented tray design developed with Moreschini for structural strength and production efficiency.
• Reinforced corner structure improves rigidity during handling and sealing.
• Maximised internal volume through four structural corners, giving more usable space than many alternative paper trays.
• Optimised paper usage, reducing material consumption without compromising tray integrity.
• Fully flat tray bottom supports stable product placement and improved shelf presentation.

Barrier options for food protection
For products that need additional protection, the process can include an optional barrier liner applied after forming. This expands the range of foods the trays can handle and supports common protective pack formats.

• Barrier liner can improve suitability for chilled or moist foods.
• Compatible with MAP (Modified Atmosphere Packaging) applications.
• Compatible with skin packaging applications, supporting strong pack appearance and product protection.

Tray formats and sizing flexibility
Paper Shape trays can be produced in defined format ranges, with the option to customise dimensions within those ranges to suit product needs.

Available tray formats include:

• 185 × 135 mm, height 30 mm
• 180 × 250 mm, height 20 mm or 35 mm
• 148 × 232 mm, height 20 mm or 30 mm