Trays are fundamental packaging components used across many industries to organise, transport, protect, and display products. When deciding between cardboard and plastic trays, businesses typically weigh durability, environmental impact, cost, and functionality. This guide compares the benefits, limitations, and environmental implications of cardboard and plastic trays to help businesses make well-informed packaging decisions.
Material Composition and Sustainability:
Cardboard trays are made mainly from paper fibres derived from virgin wood pulp or recycled content. These materials come from renewable sources, are widely recyclable, and in many cases are compostable in suitable facilities. By contrast, plastic trays are typically produced from petroleum-based polymers such as polyethylene (PE) or polypropylene (PP). Plastics offer superior moisture resistance and durability but are not biodegradable and can contribute to long-term waste if not collected and recycled properly. From a sustainability standpoint, cardboard generally has a lower end-of-life impact because it biodegrades more readily and is easier to recycle, aligning with circular-economy principles advocated by organisations such as the Sustainable Packaging Coalition and the Ellen MacArthur Foundation.
Environmental Impact and Recycling:
Overall, cardboard trays usually outperform plastic trays on environmental metrics and recyclability. Cardboard can be repulped and remade into new paper products multiple times or composted where infrastructure exists. Plastics can persist in the environment for decades or longer, and recycling rates differ significantly by polymer type and region. Inadequate recycling infrastructure and contamination issues can result in plastics ending up in landfills or the natural environment. For reliable guidance on recycling and waste management practices, consult resources such as the U.S. Environmental Protection Agency (EPA) and the How2Recycle programme.
Versatility and Customisation:
Both materials offer extensive customisation options. Cardboard is highly adaptable: it can be die-cut, creased, printed with high-quality graphics using eco-friendly inks, and finished with coatings or laminates for additional protection. These features make cardboard ideal for short runs, seasonal promotions, and visible retail display. Plastic trays are also customisable but often require specialised manufacturing and printing processes and may be less compatible with certain eco-friendly finishes. Plastics are commonly chosen when repeated reuse, precise moulding, or long-term durability is required.
Durability and Protection:
Plastic trays are prized for their strength, impact resistance, and effective moisture barriers, making them suitable for heavy or fragile items and for extending the shelf life of perishable goods. Advances in cardboard engineering—such as reinforced corrugation, laminated barrier layers, and water-resistant coatings—have narrowed the performance gap. Properly treated cardboard trays can provide sufficient protection in many handling and transport scenarios while delivering better end-of-life outcomes. When choosing a material, consider the product’s weight, fragility, storage and shipping conditions, and the intended lifespan of the packaging.
Cost Considerations:
Cost comparisons depend on short- and long-term use. Plastic trays frequently require a larger upfront investment—especially for injection-moulded or highly customised parts—but their durability and reusability can make them cost-effective over multiple cycles. Cardboard trays are typically less expensive for single-use or short-term packaging and can reduce disposal costs due to simpler recycling and composting. To determine total cost of ownership, include purchase price, protection performance, reuse potential, transport efficiency (weight and stacking), and end-of-life disposal or recycling expenses.
Consumer Perception and Market Trends:
Consumers are increasingly favouring sustainable packaging. Many shoppers expect brands to reduce single-use plastics and prefer recyclable or compostable materials when possible. Brands that adopt lower-impact options like cardboard can benefit from improved public perception, stronger customer loyalty, and differentiation in eco-conscious markets. Clear on-pack communication about material composition, recyclability, and proper disposal instructions helps maintain consumer trust and reduces contamination in recycling streams.
Regulatory Compliance and Food Safety:
Both cardboard and plastic trays must meet regulatory and food-safety standards for food-contact applications. Compliance encompasses approved materials, inks and coatings, migration limits, and hygiene during manufacture. Plastic may provide superior moisture and barrier properties for certain food products, but many cardboard systems meet food-safety requirements using food-grade liners and approved barrier treatments. For region-specific guidance on food-contact materials and regulatory expectations, consult sources such as the U.S. Food and Drug Administration (FDA) or your local regulatory authority, and consider polymer-specific data from organisations like PlasticsEurope.
Conclusion:
Cardboard trays offer clear environmental advantages—biodegradability, recyclability, and a typically smaller end-of-life footprint—making them an excellent choice for businesses prioritising sustainability and single-use scenarios. Plastic trays remain the better option where repeated reuse, superior moisture resistance, or extra-strength protection are required. The best choice depends on a balance of factors: product protection needs, customisation and branding priorities, total cost of ownership, regulatory compliance, and consumer expectations. By evaluating these criteria, aligning packaging strategy with sustainability goals, and using clear disposal instructions, businesses can select trays that meet operational needs while minimising environmental impact.
