Evolving Packaging for a Smarter Future: The Story Behind Coppice Gen 2 Trays

In food production, packaging isn’t just packaging. It’s the silent partner that protects delicate ingredients, carries meals safely through supply chains, and helps brands deliver on their promises to customers. At Coppice, we’ve always known that the best packaging solutions come from listening, adapting, and innovating.

That’s why we’re proud to introduce our Gen 2 Trays—a £750,000 investment in next-generation tooling and design that makes our bestselling aluminium trays stronger, smarter, and more sustainable.

Why Change Was Needed

Our smoothwall aluminium trays have long been trusted by food manufacturers and retailers across the world. They’re durable, versatile, and endlessly recyclable. But as demands on packaging continue to grow—from longer supply chains to new cooking technologies like air fryers—our trays needed to evolve too.

Feedback from our partners was clear:

• Trays needed to resist corner splits during high-speed filling.

• Consumers wanted clearer recycling guidance.

• Delicate products demanded greater protection in transit.

• Retailers asked for packaging that was even more efficient in cooking performance.

Engineering a Better Tray

The result is Gen 2: a smarter design that solves these challenges without disrupting existing processes.

• Base Redesign for Strength & Airflow

  We retooled the base pattern, making it more robust while also improving air circulation. The result? Stronger trays that conduct heat evenly for consistent cooking.

• Bull Nose Rib Sidewalls

  This new design feature strengthens the tray walls, adding rigidity without adding weight. It means trays can handle more pressure, both on the production line and in the consumer’s kitchen.

• Reinforced Corners

  Corners are often the weak point in food trays. Our Gen 2 design significantly improves durability, reducing cracking and protecting product integrity.

• Rinse + Recycle Messaging

  Every tray now carries a clear, consumer-friendly logo. It’s a simple way to drive higher recycling rates and reinforce aluminium’s sustainability advantage.

• Seamless Production Transition

  Despite all these upgrades, Gen 2 trays are designed for smooth line changeovers—no downtime, no headaches.

A Smarter Step for Sustainability

Aluminium has always been one of the most sustainable materials available. It’s infinitely recyclable, with 75% of all aluminium ever produced still in circulation today. With Gen 2, we’ve taken that legacy a step further by making it easier for consumers to do the right thing.

By combining clear recycling cues with engineering improvements that extend the lifespan of each tray in use, Gen 2 supports our customers’ ESG and waste reduction goals—while helping food reach consumers in perfect condition, every time.

Updating the Details: New Codes for a New Generation

With progress comes clarity. To help customers easily distinguish upgraded designs from older models, each Gen 2 tray carries a new product code:

Looking Ahead

The Gen 2 Trays are more than a product upgrade. They’re a symbol of our commitment to continuous improvement and sustainable innovation. With over 50 years of packaging expertise and Europe’s largest press and tool bank, Coppice remains a trusted partner for food businesses worldwide.

Packaging might not always take the spotlight—but when it performs flawlessly, it protects products, supports sustainability goals, and enhances the consumer experience. With Gen 2, we’ve raised the bar once again.

👉 Want to see the Gen 2 difference for yourself? Contact us at sales@coppice.net to request samples or discuss how these trays can support your business.

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