Achieve up to 90% plastic reduction, hermetic MAP sealing, and extended product freshness with PaperSeal® high-barrier paperboard tray technology.
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Engineered to withstand rigorous cold-chain logistics, high humidity, and high-speed tray sealing automation.
Get a QuoteAs a NYSE-listed leader (NYSE: GPK), Graphic Packaging International delivers fully audited ESG performance, global manufacturing scale, and award-winning barrier tray technology.
An in-depth evaluation for food processors, retail procurement directors, and packaging engineers transitioning from thermoformed plastics to sustainable fiber structures.
Food processors and multinational retailers face mounting pressure from legislation such as the EU Packaging and Packaging Waste Regulation (PPWR), extended producer responsibility (EPR) fee increases, and corporate Scope 3 emissions commitments. Rigid plastic trays made of CPET, PP, or APET represent significant environmental liabilities in the fresh food supply chain.
Barrier-lined paperboard trays solve this challenge by replacing up to 80%–90% of plastic content with sustainably sourced paperboard from certified managed forests. By utilizing a removable or ultra-thin liner, these trays deliver the exact barrier integrity required for delicate fresh proteins and ready meals while seamlessly integrating into paper recycling streams after consumer use.
Understanding gas transmission rates, moisture barriers, and flange sealing integrity in high-barrier paperboard trays.
The primary technical hurdle when converting from rigid plastic thermoformed trays to paperboard trays is achieving a 100% leak-proof, hermetic seal around the tray flange. Traditional folded paperboard trays often suffer from pinholes or gas leakage at folded corner joints, compromising Modified Atmosphere Packaging (MAP) gas mixtures (CO2, O2, N2) and shortening shelf life.
Graphic Packaging’s proprietary PaperSeal® technology overcomes this limitation through an innovative continuous sealing flange design. The liner film spans across a smooth, uninterrupted tray perimeter flange, ensuring consistent surface planarity. This design enables high-speed heat sealing with top lidding films, guaranteeing zero gas leakage and maintaining ultra-low Oxygen Transmission Rates (OTR) comparable to traditional rigid plastics.
The table below illustrates performance benchmarks for barrier-lined paperboard trays compared against traditional CPET and PP trays across key operational criteria:
| Performance Metric | Barrier-Lined Paperboard Trays (PaperSeal®) | Rigid CPET Trays | Polypropylene (PP) MAP Trays |
|---|---|---|---|
| Plastic Content Reduction | 80% to 90% Reduction | 0% (100% Virgin/Recycled Plastic) | 0% (100% Virgin Plastic) |
| Oxygen Barrier (OTR) | < 0.5 cm³/m²/24h (EVOH Liner) | < 1.0 cm³/m²/24h | > 5.0 cm³/m²/24h (Requires EVOH) |
| Moisture Barrier (WVTR) | < 1.0 g/m²/24h | < 1.0 g/m²/24h | < 0.5 g/m²/24h |
| Custom Graphic Printability | 360° Internal & External Offset Printing | Limited to External Labels / Sleeves | Limited to External Labels / Sleeves |
| Recyclability Stream | Paper/Fiber Recyclable (Post-peel) | Hard-to-recycle PET stream | Rigid PP plastics stream |
| Thermal Resistance Range | -40°C to +200°C (Cookable format) | -40°C to +220°C | -20°C to +120°C |
Tailored packaging configurations designed for specific fresh food, protein, and food service applications.
Ideal for fresh red meat, pork, poultry, fish, and hard cheeses. Features a one-piece tray blank with an EVOH barrier liner for extended shelf life under MAP conditions.
Get a QuoteSpecifically engineered for sliced meats and charcuterie. Ultra-low profile maximizes display efficiency in retail chillers while minimizing film usage.
Get a QuoteDesigned for dual-ovenable ready meals. Withstands conventional oven temperatures up to 200°C (392°F) and microwave heating, replacing CPET trays.
Get a QuoteDelivered flat to food processing plants, forming trays directly on sealing lines to optimize freight bulk, warehousing space, and inward logistics costs.
Get a QuoteVentilated paperboard tray solutions for soft fruit, tomatoes, and fresh produce. Available with or without top lidding film integration.
Get a QuoteBespoke tray structural designs engineered to fit existing automated destackers, denesters, and high-speed rotary sealer lines.
Get a QuoteThe success of converting to paperboard packaging depends on seamless machinery compatibility. We engineer trays and equipment to perform in harmony.
Procurement teams often face friction when packaging suppliers blame machinery manufacturers for line stoppages or sealing failures. Graphic Packaging eliminates this supplier friction by supplying both the barrier-lined paperboard trays and the dedicated tray-forming automation equipment.
Our packaging machinery division designs custom tray-denesting units, high-speed lining systems, and flange-forming modules capable of running seamlessly on leading industry tray sealers such as G.Mondini, Sealpac, and Multivac systems. This single-source accountability ensures guaranteed line speeds, minimal operational downtime, and optimal hermetic sealing rates.
Emerging technology shifts and regulatory landscapes driving the next decade of sustainable food packaging design.
Transitioning from ultra-thin polymeric liners to water-dispersed, bio-based barrier coatings. This technological leap will allow 100% repulpability in standard paper recycling mills without requiring physical liner separation by consumers.
Integration of printed conductive inks, QR codes, and micro-sensors directly into the outer paperboard surface, providing cold-chain tracking, shelf-life verification, and anti-counterfeit measures across international export routes.
With regulations requiring minimum 80% plastic reduction across fresh produce and protein categories worldwide, barrier-lined paperboard trays serve as the primary compliant carrier format for multinational retail brands.
Global procurement requires stability, compliance, and multi-facility redundancy. Graphic Packaging International operates fully integrated paperboard mills, converting facilities, and machinery engineering centers across North America, Europe, and Asia-Pacific.
Our fully transparent supply chain guarantees continuous raw material availability, certified sustainable forestry sourcing (FSC, PEFC, SFI), and strict adherence to global food contact safety standards (FDA, EU 1935/2004, BRCGS).
Get a QuoteAddressing common queries raised by food processors, packaging engineers, and enterprise procurement teams.
Contact our packaging engineering and technical sales teams to request samples, schedule line audits, or receive customized structural quotes for your brand.
Graphic Packaging International is an equal opportunity employer dedicated to innovation, transparency, and sustainable growth across global packaging supply chains. All corporate operational data and sustainability metrics are published in accordance with international auditing standards.