Design Study-Thermoprocessed Food Containers Injection Molded Half-Size Steam Tray for Storage and Serving of Processed Foods

The purpose of this program was to design, select, and evaluate plastic materials for an injection molded, half-size steamtable tray to be used for the storage, reheat, and serving of processed food items at government facilities. In performance of this study, Springborn Laboratories, Inc. conducted a survey of plastic materials for use as a food tray based on literature stated properties, followed by a laboratory investigation of heat distortion temperature, and flexural modulus at elevated temperatures. Candidates include polysulfone, talc filled polypropylene, poly4 methyl pentene-1, polyacetal, talc filled Nylon 612, polycarbonate, and Nylon 12. PVDC and polyester-based cover films were also investigated. A design was developed for the food tray along with production cost estimates for the tray based on the three most promising plastic materials, polycarbonate, polysulfone, and talc-filled polypropylene. Finally, a prototype single-cavity mold was designed and fabricated and injection molding trials were conducted. Samples of trays in both 0.045- and 0.090-inch wall thickness were submitted to NARADCOM for evaluation of dimensional stability at elevated temperatures and food storage performance.