Molded Pulp Trays for Coffee Capsules and Pods: Secure, Compostable Retail Packaging

Coffee capsules and pods are small, dense, and easily knocked out of alignment in a carton, and the brand selling them often carries a sustainability claim that plastic blister trays undercut. A molded pulp tray locks each capsule into its own cavity, survives parcel and retail handling, and composts with the packaging the customer already expects to dispose of.

The Scenario: A tray that holds every pod

Capsule tray design faces three challenges:

Pain Points

• Capsules shift or pop out of loose inserts, arriving dented or misaligned in the retail display;
• Plastic blister trays contradict the compostable story of premium coffee brands;
• Tight cavity tolerances risk jamming pods during manual or automated filling.

The Solution: Three tray solutions

Three design choices deliver a secure, brand-true tray:

1. Per-capsule cavities Individual cavities with light interference fit hold each capsule firmly in transit and display.

2. Compostable fiber construction Unbleached molded pulp with EN 13432-compliant compostability keeps the pack true to the brand story.

3. Filling-tolerant draft angles Draft angles and tapered walls let capsules seat easily by hand or on a fill line without jamming.

The Result: Secure pods, on-brand shelf

Capsules arrive aligned and intact, and the tray composts with the packaging story intact.