Biscuit case: reusable trays designed for safe and efficient baking processes

When an industrial biscuit manufacturer needed to improve its baking and storage process, the challenge went beyond packaging. The goal was to create a reusable solution that would protect fragile products, support efficient handling, and meet strict hygiene requirements.

DW Reusables was asked to develop a tray that could perform reliably throughout the production process.

In industrial bakeries, different types of biscuits cannot always be baked and processed simultaneously. This creates a need for temporary storage solutions that keep products safe, dry and free from contamination before final packaging.

The existing solution, based on metal boxes, created several issues.The boxes were not stackable, making storage inefficient and increasing logistical complexity. Their design also made cleaning and drying more time-consuming, creating challenges in maintaining efficient hygiene processes.

For delicate products such as macarons, the lack of protection during handling also led to product damage.

A more efficient, food-safe and reusable solution was required.

DW Reusables developed a custom reusable plastic tray tailored to the specific requirements of industrial baking.

The design introduces a stackable system where the bottom of each tray acts as a sealing lid for the tray below. This ensures that biscuits are protected from air exposure and external contamination during storage.

To prevent damage to fragile products, the trays can be equipped with up to nine internal dividers, keeping biscuits separated and stable during handling. The high dimensional accuracy of the trays also makes them suitable for automated handling and pick-and-place systems.

In addition to product protection, the design supports efficient cleaning and hygiene management. Integrated drainage holes allow water to drain quickly and enable faster drying after washing, while the smooth geometry minimises areas where residues can accumulate. An ergonomic handle further improves usability for operators throughout the process.

The new tray system improved both product quality and operational efficiency.

Fragile biscuits can now be stored and handled without risk of damage, while the sealed stacking system ensures optimal protection against contamination. The improved cleanability supports hygiene standards and reduces downtime in the cleaning process.

From a logistics perspective, stackability simplifies storage and handling, reducing complexity compared to the previous metal boxes.

The investment in a dedicated mould proved to be cost-efficient over time, thanks to reduced waste, improved process efficiency and better product consistency. The trays are designed for long-term use and are fully recyclable at the end of their lifecycle.

The new tray system improved both product quality and operational efficiency.

Fragile biscuits can now be stored and handled without risk of damage, while the sealed stacking system ensures optimal protection against contamination. The improved cleanability supports hygiene standards and reduces downtime in the cleaning process.

From a logistics perspective, stackability simplifies storage and handling, reducing complexity compared to the previous metal boxes.

The investment in a dedicated mould proved to be cost-efficient over time, thanks to reduced waste, improved process efficiency and better product consistency. The trays are designed for long-term use and are fully recyclable at the end of their lifecycle.

We combine technical expertise, industry knowledge, and genuine collaboration to create reusable packaging solutions that perform in your operations today and evolve with your needs tomorrow.