Custom-size trays made to order

A custom-size tray comes to the fore when the shape of the product, the required portion or the appearance of the pack calls for a dedicated design. In such cases, we design the dimensions and shape of the right tray starting from the product to be packed. A custom look, printing, a special shape and a material chosen for the application can all be part of the consultation. At Kollár Pakk we review the development criteria together with the filling, sealing and usage process.

Sizing that starts from the product

For preparation, besides the length, width, height and weight of the product, we also need to know how it is placed. It matters whether one or several pieces go into the tray and in what position the components must stay. The internal space and the outer overall dimensions are separate data: the former relates to the contents, the latter to the machine, the shelf and the outer packaging. The width and outline of the flange are also determined by the planned sealing. Sizing is therefore best started with a product sample or a detailed drawing.

Material selection according to use

We choose the material of the custom tray based on the product and its entire path of use. Cold counter sales, hot filling, freezing or later heating impose different requirements. The moisture and fat content of the contents and the expected mechanical protection also matter. In modified atmosphere packaging, the required gas barrier is a joint task of the tray and the lidding material. Material use should be assessed together with appearance, so that the aesthetic concept also fits the packaging function.

Shape, printing and sealing

A special shape and printed appearance can help make the product recognisable, but the handling of the pack must also be kept in mind. How the lid or lidding film attaches, how the customer opens the pack and where the label goes are important questions from the very start of the design. With an existing machine, the tool and the available working space limit the options. For a new design, we adapt the tray to these conditions. A manufacturable solution is determined jointly by the geometry, the material and the planned order quantity.

Sample testing before finalisation

A custom tray should be tested with the actual product. Besides trial filling, sealing, ease of opening and the handling of the filled pack can also be checked. Nesting, destacking and storing the trays affect work at the packing station. A transport trial can show where the pack is under load and what outer packaging it needs. This experience helps refine the dimensions and details before the design is finalised.

To request a custom tray, please send us the product data, the required pack format, the expected quantity and a description of the packaging process. If a drawing, an existing tray or a design concept is available, that also helps the preparation. Based on your requirements, our colleagues will examine the options for implementation and help put together the technical basis needed to develop the tray.