Thermoformed paper trays originated over 30 years ago, born out of necessity as a result of the introduction of the microwave oven. At the time, most frozen foods and dinners were packaged in aluminum foil containers. With the advent of the new microwave technology, food processors needed containers made from materials that would be microwave-friendly. Of course aluminum foil containers could not be put into microwave ovens without dire consequences. Because paper is microwave-friendly, paper companies saw this as a great opportunity to enter a new market. In response, they developed a heavyweight paperboard coated with a thin layer of polyester, a high temperature plastic. In doing so, they developed a material that would not only prove to be microwave-friendly but could also be used in conventional gas and electric ovens, thereby creating a truly “dual ovenable” material.
Adapting the existing technology from the forming of paper plates, the original developers used this process to form this new material to produce a three-dimensional paper food tray. This tray could not only be used in the packaging of frozen foods but also for food service packaging and fast food. Because the process utilizes heated dies to form the paperboard, it quickly acquired the name of “thermoforming.” Thermoformed paper trays and containers are created via a special manufacturing process that yields final thermoformed products that are incredibly lightweight, surprisingly strong. Thermoformed paper products are fast becoming a category killer for food processors/food service packaging companies looking for a better solution.
Further, because this new dual ovenable material was recognized as being made from a renewable, sustainable resource and because as disposable cookware and bakeware it provided superior performance, it was soon replacing aluminum foil containers and high temperature plastic trays for many applications. Today, thermoformed paper trays are not only being used for frozen foods and food service packaging, but they have also found a niche as commercial bakeware when disposable baking pans are more desired than standard metal commercial baking pans or baking trays.
Solut! is proud to have associates who were there at the beginning over 30 years ago and throughout the years. We have continued to develop and expand the technology to new areas.
