North America Foam Trays Market

Takeaway Food Startups Generate Income Sources for Manufacturers During COVID-19 Pandemic

Stakeholders in the packaging industry have been working at break-neck speeds to meet the unprecedented demand from food & beverage (F&B), pharmaceuticals, and industrial packaging sectors during the COVID-19 crisis. Polystyrene foam products have been gauging high demand in supermarkets for the packaging of meat, eggs, and vegetables, among others. The ever-expanding eCommerce industry is creating revenue opportunities for manufacturers in the North America foam trays market.

Due to the partial and permanent shutdown of many restaurants, manufacturers in the North America foam trays market are capitalizing on revenue opportunities through takeaway food services. An increasing number of food startups are creating value-grab opportunities for foam tray manufacturers. Manufacturers are becoming competitive in their pricing to get an edge over other suppliers.

Recycling and Standardized Burning of Polystyrene Helps to Reduce Environmental Footprint

Since disposing polystyrene is becoming a major environmental issue, manufacturers in the North America foam trays market are increasing the availability of recyclable polystyrene. Polystyrene food containers, syringes, and cutlery are shipped to recycling facilities where it is sorted and cleaned. The polystyrene is shredded into tiny pieces and later exposed to heat, which causes it to melt into a paste. This paste is compressed and dried into pellets or blocks before it is shipped to another facility where new produced can be made.

Since recycling of polystyrene can be a potentially expensive and complex procedure, waste disposal companies are taking advantage of this opportunity within a challenge to efficiently burn and dispose polystyrene foam trays in a standardized manner.

Automation to Drive Changes in Product Protection Landscape

The North America foam trays market is projected to cross US$ 1.2 Bn by 2031. EDL Packaging Engineers - a specialist advancing in shrink wrapping and bundling packaging machinery, is now offering automatic packaging solutions for foam products, as automatic wrapping significantly reduces labor and material.

Apart from product innovations, automation is one of the key drivers, which is contributing to the growth of the North America foam trays market. This is evident since total enclosure protects foam products prior to conversion.

Deep Foam Produce Trays Ensure Food Freshness and Hygiene

F&B applications are creating stable revenue streams for manufacturers in the North America foam trays market. Manufacturers are bolstering their production for deep foam produce trays made from highly compact foam materials that ensure food does not leak through and prevents bacterial build-up. They are increasing their focus on 100% recyclable foam trays.

Manufacturers in the North America foam trays market are increasing the availability of deep foam produce trays that protect and preserve food freshness. Innovative foam trays help to maintain temperature, ensure hygiene, and are available in different sizes. These trays are integrated with foam insulators, which help to maintain food freshness for long.

Disposable Foam Trays Gaining Popularity in Cafeteria Programs

There is a growing demand for disposable foam trays for meat packaging applications. Manufacturers in the North America foam trays market are increasing the production of sturdy and lightweight foam trays in multiple sizes for diverse applications. Innovative 5 and 6 compartment school lunch trays are creating income sources for manufacturers.

Companies in the North America foam trays market are expanding business through operator school feed and cafeteria programs. Thus, to achieve this, manufacturers are deploying rigid construction and portion control convenience in foam trays. Manufacturers are designing foam trays that resist bending and buckling. Disposable foam trays are eliminating the need for dishwashing and expensive permanentware replacement. Non-laminated satin foam trays are ideal for food, cafeteria, and employee feedings. Manufacturers are designing elegant, high gloss laminated satin white serving foam trays. Caterers are finding these trays ideal for lap trays and banquet lines.

Analysts’ Viewpoint

The burgeoning growth of the eCommerce industry is generating revenue streams for foam tray manufacturers during the ongoing COVID-19 pandemic. Though recycling of polystyrene is an effective strategy to reduce environmental waste, the process is potentially expensive and difficult. This explains why the North America foam trays market is slated to clock a CAGR of 2.7% during the forecast period. Thus, recycling companies should look for this opportunity within challenge to commercialize recycling processes and gain cognizance about government schemes that support recycling activities. As such, manufacturers are increasing the production in heavy supermarket foam trays, foam 4D supermarket trays, and lightweight snack trays.

North America Foam Trays Market: Overview

• Foam trays are primarily used to cushion packaging and dunnage products. Foam trays are generally made from polyethylene, polypropylene, polyester, polystyrene, and other materials.
• Demand for food packaging in North America is increasing at a high rate due to rise in consumer interest toward consumption of fresh products with an extended shelf-life and controlled quality. This helps food packaging manufacturers design, and develop new and safe packaging. The U.S. accounted for a major share of the packaging market in North America in 2020. The market in the country is expanding at a faster pace driven by an increase in population.
• The U.S. is engaged in food law harmonization work in coordination with Codex Alimentarius and different government representatives from the FDA and USDA. The Foodservice & Packaging Institute (FPI), American Frozen Food Institute (AFFI), and Molded Pulp Environmental Packaging Association (IMFA) are some of the food-related associations, which ensure greater food safety, including their manufacturing, testing, packaging, and all activities.
• Polypropylene and polyester foam trays are used in food packaging, automotive, insulation, and protective packaging. In the automotive industry, polypropylene foam trays are used for a number of lightweight parts, while polyester foam trays are preferred as polyester foam trays offer better stability over heat. Other applications of foam trays include general purpose blisters, graphic arts, skin packaging, and stationery supplies.
• Polystyrene foams are commonly known as expanded polystyrene foams (EPS). They are lightweight cellular plastic materials that consist of small hollow spherical balls. They are widely used as packaging medium in North America.
• Polystyrene foam trays are a more sanitary form of food packaging, as polystyrene foam trays are disposable. Polystyrene foam trays are also shatter resistant, even in extreme temperatures.

Growth Drivers of North America Foam Trays Market

• The process cycle of foam formation is less complex and consists of fewer phases compared to the production of plastics through the polymerization process. Foam trays are cost effective compared to other plastics. Foam trays are also cost effective compared to other paper and plastic tray products as the production cost of foam is low. The labor cost for manufacturing foam trays is also low. Foam trays possess properties such as superior cushioning, impermeability to moisture, cost effectiveness, robust packaging, and convenience. Rise in demand for cost-effective food service solutions is likely to boost the foam trays market.
• Packaged food is less exposed to the environment. Therefore, there are fewer chances of exposure of the food to air, moisture, and oxidation. These factors are responsible for the fermentation of food. Demand for foam trays in meat, seafood, and poultry industries is high, as people are more inclined toward hygienic and safe food. Processors, retailers, and distributors of food offer protein products with foam packaging to provide consumers with fresh and frozen products. Demand for clean, covered, and cold food is high among customers. Thus, demand for foam trays is driven by food safety issues. Rise in demand for foam trays in meat, seafood, and poultry industries in North America is driving the foam trays market in the region.

Key Challenges of North America Foam Trays Market

• Foam products made of polystyrene foam are harmful to the human health and the environment, since they take a long time to decompose. Foam breaks down so slowly that it may sit in landfills for 500 years, according to the Environmental Action Association.
• Various substitutes of foams are available in the market. They include bagasse-based containers, corn plastic containers, and compostable paper containers. Bio-based materials reduce the use of fossil fuels and associated greenhouse gas emissions by replacing petroleum-based products. Rise in consumer demand and government support is boosting the bio-based products industry.
• People are increasingly becoming aware of the environmental hazards of polystyrene foam. Several cities are banning single-use polystyrene foam products. For instance, the New York City implemented a ban on single-use polystyrene foam product in January 2019.

Lucrative Opportunities for Players in North America Foam Trays Market

• More than 118 million pounds of expanded polystyrene (EPS) were recycled in 2016. THis also includes 63 million pounds of customer packaging and 55.7 million pounds of postindustrial packaging, according to the 2016 EPS Recycling Rate Report. According to the EPS Industry Alliance, EPS has achieved an average recycling rate of 15%, one of the highest of the plastics family, over the last decade.
• Pyrowave and Ineos Styrolution America LLC have formed a strategic partnership to support Pyrowave’s North American polystyrene recycling project. The objective of this project was to demonstrate the recyclability of postconsumer polystyrene packaging using Pyrowave’s catalytic microwave depolymerization (CMD) technology.
• Pyrowave plans to install additional systems in other parts of North America. Pyrowave spent three years for the exploration of echnology on postconsumer polystyrene waste. Now, the company can process approximately one to three tons per day of postconsumer polystyrene material. Pyrowave and Agilyx received a US$ 50,000 grant from the Foam Recycling Coalition to purchase equipment to allow for in-house processing of recycled polystyrene.

Leading Players in North America Foam Trays Market

• Key players such as Tekni-Plex, Inc., PACTIV Corporation, Novipax, Anchor Packaging Inc., Placon Corporation Inc., Coveris Holdings S.A, D&W Fine Pack LLC, Genpak LLC, Berry North America Inc., Ecopax LLC, Dart Container Corporation, Cascades Inc., and Atlas Holdings LLC. are focusing on expanding their global footprint through strategic capital allocation and increasing production capacity
• Players operating in the foam trays market in North America are adopting various organic and inorganic growth strategies such as mergers & acquisitions, new product launches, strategic collaborations, expansion, and joint ventures to expand their product portfolio and business operations.

Foam Trays Market Snapshot

North America Foam Trays Market – Segmentation

TMR’s research study segments the foam trays market in North America by material, type, application, and country. This report presents extensive market dynamics and growth trends associated with different segments and explains how they are influencing the growth of the foam trays market in North America.