How MarCon’s Plastics Division Manufactures High-Performance Freezer Trays

MarCon’s Plastics Division is a leading producer of durable, food-safe freezer trays used across food processing, storage, and distribution industries. With decades of experience in polymer engineering and tooling, the division specializes in producing high-quality, injection-molded trays that are engineered for longevity and optimal freezing performance. In addition to a full range of standard configurations, MarCon provides custom trays upon request to meet unique storage, processing, and equipment-fit requirements.

What Are Freezer Trays?

Freezer trays are rigid, multi-channel containers designed to freeze and store evenly portioned quantities of food. They are commonly used by commercial kitchens, food manufacturers, and bulk-storage operations. Unlike consumer ice trays, industrial freezer trays feature:

• Multiple channels (pints or quarts)
• Thick, durable walls for repeated freezing cycles
• Materials engineered for excellent low-temperature performance
• Rigidity that allows efficient stacking and cold-air circulation

These trays maintain structural integrity, resist cracking, and deliver consistent freezing results over long-term use.

Materials Used in Manufacturing

MarCon manufactures rigid plastic trays typically from:

• Polypropylene (PP) – highly durable, food-safe, and freezer-resistant
• Polyethylene (PE) – flexible, impact-resistant at low temperatures

These polymers provide strong performance in commercial freezers, where temperatures, moisture, and handling demands are more extreme than in household settings.

How MarCon Injection Molds Its Freezer Trays

MarCon’s Plastics Division uses industrial injection-molding systems to produce its trays with exceptional accuracy and consistency. Injection molding allows for smooth interior surfaces, strong structural ribs, and precise channel dimensions that ensure uniform freezing.

1. Material Preparation

Plastic pellets are loaded into an injection-molding hopper. Depending on the final tray specifications, PP or PE is dried and prepared for processing.

2. Melting and Mixing

The pellets are heated and mixed inside the molding machine’s screw barrel. For polypropylene, melt temperatures typically reach 180–240°C, creating a homogeneous molten plastic ready for molding.

3. Injection Into the Mold

The molten plastic is injected under high pressure into a custom steel mold.
The mold defines all aspects of the tray’s design, including:

• The number of channels (pints or quarts)
• Wall and base thickness
• Rim geometry
• Texturing or branding

MarCon’s use of multi-cavity tooling increases efficiency, allowing several trays to be produced each cycle.

4. Controlled Cooling

Freezer trays require highly uniform cooling to prevent warping, bowing, or sink marks. The mold contains internal water-cooling channels that maintain consistent temperatures. This step is critical for trays with deep channels.

5. Ejection and Removal

Once solidified, the mold opens and ejector pins release the tray. The parts are inspected for dimensional accuracy and surface quality before moving to finishing.

6. Finishing and Quality Control

Post-processing includes trimming any excess material and verifying:

• Dimensional tolerances
• Channel volume accuracy
• Freeze-temperature stability
• Food-contact compliance

Only trays meeting strict standards move on to packaging.

Standard Freezer Tray Dimensions

MarCon offers an extensive catalog of freezer trays in multiple capacities and channel configurations. Below are the current standard sizes available.

3930 — 7-Channel Quarts

• 32.50 × 23.25"
• 32.50 × 20.50"
• 28.25 × 23.25"
• 28.25 × 20.50"

4550 / 4489 — 8-Channel Pints (White / Black)

• 31.50 × 23.625"
• 31.50 × 21.125"

4469 — 8-Channel Pints

• 32.25 × 22.50"
• 32.25 × 20.25"
• 32.25 × 18.50"
• 27.75 × 22.50"
• 27.75 × 20.25"
• 27.25 × 18.50"

4487 — 6-Channel (1.50 or 1.75 Quarts)

• 30.50 × 21.125"

4490 — 7-Channel Pints

• 28.00 × 21.125"

Custom Trays Available on Request

In addition to standard models, MarCon’s Plastics Division provides custom freezer tray design and production. Customization options include:

• Channel size (pints, quarts, custom volumes)
• Channel count
• Wall thickness and stiffness
• Material choice (PP, PE, or blends)
• Unique dimensions for equipment compatibility
• Custom colors or labeling

Engineers collaborate with clients to ensure trays meet strict functional, regulatory, and environmental requirements.

Conclusion

Through advanced injection-molding technology, food-safe materials, and precision tooling, MarCon’s Plastics Division produces freezer trays built for demanding commercial applications. Their wide range of standard configurations—and the ability to custom-engineer trays—makes MarCon a trusted partner for industries that rely on durable, consistent, and efficient freezing solutions.