How to Choose the Perfect Food Tray for Your Restaurant or Food Truck

The right food tray depends on three things: what you serve, how far it travels and how long it sits before someone eats it. A crisp waffle needs a different tray than saucy nachos, and a food truck has different limits than a sit-down restaurant or a catering job.

This guide covers the main types of trays used in food and beverage service, standard tray sizes and capacities, the materials that hold up to grease and heat, and the questions to ask before you order. It ends with a checklist and answers to the questions owners ask us most.

If you want to see finished examples first, browse our custom printed food trays.

Types of Trays in Food and Beverage Service

The word "tray" covers two different things in a restaurant. Service trays are the reusable trays staff use to carry plates and drinks. Disposable food trays are the paper or board trays the food is served in and taken away in. Both matter, but they solve different problems.

Reusable service trays

Front-of-house teams typically use a few standard tray types:

• Round beverage trays: small, often with a non-slip surface, for carrying drinks to tables.
• Oval or large rectangular serving trays: used to carry several plated meals at once.
• Cafeteria trays: flat rectangular trays customers carry through a self-service line.
• Room service trays: used in hotels to carry a full meal to a room.
• Platters and catering trays: for buffets, parties and shared dishes.

The rest of this guide is about the second group: disposable trays the food actually sits in. That is where your choice affects food quality, mess and branding on every order.

Disposable food trays by menu item

Most menus need two or three of these, not ten. Start with the items you sell most and pick a tray that suits each one. A general cardboard tray can then cover the rest.

If you sell crepes or other handheld desserts, our guide to common crepe cone packaging mistakes covers the sleeve side of the same problem.

Food Tray Sizes: Standard Sizes and Capacities

Food tray sizes are described in different ways depending on the type. Paper boat trays are usually sold by how much food they hold. Catering pans use standard "full" and "half" sizes. Custom trays are made to your own dimensions. Waffles and bubble waffles sit better in trays made for waffles.

Paper food tray sizes by capacity

In the US, disposable paper food trays are commonly labeled by a number that matches their capacity in hundredths of a pound. Exact dimensions vary from maker to maker, so treat this as a guide to capacity, not a size chart:

The 2 lb tray is the workhorse for most food trucks and fast-casual menus. It fits a burger with a side or a full plate of loaded fries. For greasy foods, look for a 2 lb tray in a coated board with firm walls rather than a thin, uncoated one.

Half tray vs full tray for catering

Catering trays follow the standard steam table pan system. A full-size pan is nominally about 12 by 20 inches. A half-size pan is about half that footprint, roughly 10 by 12 inches, so two half pans fit in the space of one full pan. Smaller third and quarter pans also exist. Pans come in different depths, and a deep half pan can hold more than a shallow one, so always compare depth as well as footprint.

A half tray holds about half the food of a full tray of the same depth. To decide which you need, don't guess by guest count alone. Work out your portion size per guest, multiply by the number of guests, and then pick the tray that holds that amount. Half trays are easier to carry, keep warm and swap out on a buffet, which is why many caterers use several half trays instead of one full tray.

Choosing a serving tray size for a party

For party platters, such as fruit and veggie trays or a relish tray, the question is how much space each item needs. Lay out the food on a sheet of paper the size of the tray you are considering. Leave space between groups of food so guests can pick things up without knocking the rest over. If the layout feels crowded, go one size up or use two trays.

How to measure a menu item for a custom tray

1. Plate your item exactly as you serve it, with all toppings and sides.
2. Measure the length and width at the widest points.
3. Measure the height, including tall toppings or stacked layers.
4. Add a little clearance on each side so the food isn't pressed against the walls, and more for saucy foods.
5. Decide if you need compartments, and measure each section separately.
6. Order samples in your chosen size and test them in a real service before a full run.

A tray that is too big makes portions look small and wastes board and storage space. A tray that is too small lets food hang over the edges and sauces run out. Cone Sleeves makes custom sizes, so you can match the tray to the food rather than the other way around.

Materials, Grease Resistance and Food Safety

The material decides how long a tray holds up under hot, greasy or wet food. Here is how the common options compare: For heavier loads such as nachos or fried chicken, custom cardboard food trays hold their shape.

Grease resistance and the Kit rating

Grease resistance in paper and board is often measured with the Kit test, which gives a rating from 1 to 12. A higher rating means the material resists oil and grease for longer. Dry snacks need only a low rating. Standard fast food needs a medium rating. Fried chicken, loaded fries and anything sitting in sauce needs a high rating.

When you compare trays, ask what coating the tray uses and how it performs with oily food. Then test it yourself, because a rating doesn't replace a real trial with your own menu.

Hot, cold and wet foods

Hot fried food is hard on trays. Steam softens board from the inside, and grease attacks it from the surface. Leave a gap for steam to escape so fries stay crisp. For cold and frozen items, the problem is condensation. Ice cream and chilled desserts make water bead on the tray, so pick a moisture-resistant coating. For very wet dishes such as soups and stews, a tray is the wrong format; use a cup or bowl.

FDA compliance and food-safe materials

Any tray that touches food directly should be made from food-safe materials. In the US, that means materials that meet FDA rules for food contact. Ask your supplier to confirm FDA compliance for both the board and any coating on the food side.

Be careful with vague labels. A word like "certified" on a spec sheet means little unless the supplier can tell you what standard it refers to. Cone Sleeves uses FDA-compliant food-contact materials and prints with soy- and vegetable-based inks, so your trays are food-safe on the side that matters. If your tray has a printed inside surface, ask the same question about the inks: they must be food-safe too, and FDA rules apply to them as well.

Recyclable, biodegradable and compostable options

More customers now ask what happens to packaging after the meal. Plain paperboard trays are widely recyclable when they are clean. Heavily soiled trays are often not accepted for recycling, so check what your local program takes. Board with plant-based coatings is often sold as compostable in commercial facilities, but those facilities are not available everywhere.

Cone Sleeves offers recyclable and biodegradable options. If you choose them, say so on the tray. A small recycling symbol or a short disposal note tells customers what to do and shows your effort. Keep claims accurate: only print "recyclable" or "biodegradable" if the tray you ordered actually is.

Choosing Trays for a Food Truck

Food trucks have limits that restaurants don't. Space is tight, service is fast, and customers often eat standing up or walking. Choose trays with those limits in mind.

• Flat-packed storage: trays that ship flat take up far less room than pre-assembled ones. Check how quickly staff can fold them during a rush.
• Stackability: trays that nest or stack save space on a small counter.
• One-handed carrying: customers need to hold the tray and a drink, so pick a stiff base that doesn't bend.
• Wind and weather: light trays blow away at outdoor events. A heavier board or a deeper tray stays put.
• Fewer formats: two or three tray sizes that cover the whole menu are easier to stock than six.

For burgers and sandwiches, a dedicated tray keeps toppings in place and leaves room for a side. Our printed burger trays for food trucks are a common starting point. For fries and snacks, a deeper tray with firm walls works better.

Printing and Branding Your Food Trays

A printed tray is in front of your customer for the whole meal, and often in their photos. That makes it one of the most seen pieces of branding you own.

Where to print

The outside walls are what people see while you carry the tray to them. The inside base shows up as the food is eaten, which is a good spot for a message, a pattern or a social handle. Keep the most important elements, such as your logo, on the outer walls, where grease and sauce won't cover them.

Print methods and finishes

CMYK printing reproduces photos and full-color artwork. PMS (Pantone) printing matches exact brand colors from order to order. Coatings such as gloss and matte change the look and add some protection; spot UV can highlight a logo. Foiling, embossing and debossing are less common on everyday food trays but can work well on premium dessert or bakery trays. Cakes and pastries travel upright in custom dessert trays.

Choosing colors

Pick colors that match your brand and your food. Kraft and earthy tones suit bakeries and natural brands. Black and white feel clean and upscale. Bright colors suit family and dessert shops. Whatever you choose, keep strong contrast between your logo and its background so it reads from a distance.

Ordering, Cost Drivers and Storage

What affects the cost

The main cost drivers are quantity, material, size, print coverage and finishes. The minimum order is 100 units, and volume discounts lower the unit cost on larger runs. A custom shape or compartments add a cutting setup. More print coverage and special finishes add steps to production.

Planning quantities

Count how many trays you use in a normal week, then plan for busy periods and events. Order enough to cover your next reorder window with a small buffer, but don't order more than you can store well. Production takes 4–6 business days after proof approval, with rush options available, and shipping is free to the USA, Canada, the UK and Australia.

Storage and handling

Store trays flat in a dry place, off the floor and away from heat and steam. Damp board loses strength and can warp before you use it. Use older stock first, and keep a small supply near the line so staff aren't running to the back during a rush.

Seasonal planning

Menus change with the seasons, and trays should too. Ice cream shops need more cone trays and holders in summer, such as our printed ice cream cone trays. Comfort foods and fried items often pick up in fall and winter. A seasonal print run, such as a holiday design, is an easy way to refresh your look without changing your whole packaging range.

Food Tray Selection Checklist

• Each main menu item has a tray type that fits its shape and weight.
• Sizes are measured from real plated portions, not guessed.
• The coating matches the grease, heat and moisture of the food.
• Materials are FDA compliant for direct food contact.
• Trays have been tested in real service with staff and a few trusted regular customers.
• Storage space is planned, and trays are flat-packed where possible.
• Your logo sits where food and sauce won't cover it.
• Any recyclable or biodegradable claim printed on the tray is accurate.

FAQs

What are the different types of trays in food and beverage service?

Service trays include round beverage trays, large oval or rectangular serving trays, cafeteria trays, room service trays and catering platters. Disposable food trays include boat trays, burger trays, fries trays, hot dog trays, nacho trays, combo meal trays and dessert trays. Most restaurants use both kinds.

What is the standard food tray size?

There isn't one standard size for all food trays. Paper boat trays are usually labeled by capacity, from #25 for a quarter pound up to #500 for five pounds. Catering pans use full-size and half-size formats. Custom trays are made to fit your food. Folded crepes are easier to carry in trays shaped for crepes.

What is the difference between a half tray and a full tray?

A full-size catering pan is nominally about 12 by 20 inches, and a half-size pan is about half that footprint. At the same depth, a half tray holds about half the food. Work out portions per guest to choose between them.

What is the best 2 lb food tray?

Look for a #200 size tray made from coated paperboard with firm walls and good grease resistance. It should hold a burger and a side or a full plate of loaded fries without bending. Test a sample with your greasiest item before ordering in bulk.

How do I choose the right size serving tray for a party?

Start from how much food each guest will eat and how many guests you expect. For platters, lay the food out on paper cut to the tray size and leave space between groups. If it looks crowded, go up a size or split the food across two trays.

When you know what your menu needs, send us your items and sizes through the free food tray quote form. Our team will suggest a material and size, and our free design service can turn your logo into a print-ready tray.