Etihad Airways: High-Speed Tray Sealing for Premium Inflight Meals at 150 Packs Per Minute
When Etihad Airways launched its new A380 service, it needed inflight meals that looked as good in the cabin as they did in the kitchen — and packaging tough enough to survive the journey there. Packaging Automation (PA) delivered a high-speed tray sealing solution that protected meal integrity, eliminated "ballooning" in the oven, and reached a combined output of 150 packs per minute.
The challenge: presentation and durability at altitude
Premium airline catering lives or dies on presentation. For Etihad's flagship A380 service, traditional packaging was letting meals down: the movement of the aircraft, plus reheating in onboard ovens, left meals looking tired and disturbed by the time they reached the passenger.
Etihad needed a packaging method that would:
- Maintain meal presentation from kitchen to seat, despite aircraft movement
- Withstand reheating in aircraft ovens without distortion or "ballooning"
- Keep pace with high-volume catering production
- Deliver a consistent, premium dining experience across thousands of meals
The airline approached PA for a robust tray sealing solution that could hold meal integrity all the way through the catering chain.
The solution: the Eclipse SL4 high-speed tray sealer
PA guided Etihad through the move from traditional packaging to automated tray sealing, demonstrating the Eclipse SL4 tray sealer in a live production environment at a local ready-meal facility so the team could see the technology working at speed.
The project was de-risked in PA's on-site Trial Facility, where the engineering detail was proven before any line investment:
- Material compatibility testing — trays and lidding films were validated for use in aircraft ovens, confirming they could handle reheating without failing.
- Castellated sealing profiles — special profiles were engineered to vent air during heating, preventing the "ballooning" that distorts meals and breaks seals.
- Easy-open lidding films — PA worked directly with film suppliers to develop peelable films, so cabin crew and passengers get a clean, effortless open every time.
This combination of validated materials and bespoke tooling meant Etihad moved to production with the packaging behaviour already proven — not discovered on the line.
The results
Etihad installed high-speed Eclipse SL4 tray sealers, achieving a combined output of 150 packs per minute. The robust seal and vented profile design delivered measurable operational and presentation gains:
Outcome
| Outcome | Result |
|---|---|
| Combined line throughput | 150 packs per minute |
| Oven “ballooning” | Eliminated via castellated venting profiles |
| Meal presentation | Maintained from kitchen to passenger |
| Lid opening | Easy-peel, passenger-friendly films |
| Material suitability | Validated for aircraft-oven reheating |
The result is faster production, a more durable pack, and a premium inflight dining experience that holds up under real cabin conditions.
Why high-speed tray sealing works for airline catering
For caterers and airlines weighing up their packaging options, the Eclipse range brings the qualities that matter most at scale: high throughput to match catering volumes, energy-efficient motion control technology, reliable seal integrity for transport and reheating, and bespoke tooling and film development for application-specific challenges like oven venting.
Prove it before you commit: the PA Trial Facility
As with Etihad, every PA project can be validated before investment. Our Trial Facility lets you test your own trays, films, and products on the actual machinery — confirming seal quality, presentation, and throughput before a single machine reaches your floor.
Ready to elevate your inflight or ready-meal packaging?
Discover how PA's high-speed tray sealing solutions can improve presentation, durability, and output across your line.
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FAQs
What output can the Eclipse SL4 tray sealer achieve?
In Etihad Airways' installation, the high-speed sealers reached a combined output of 150 packs per minute.
How does tray sealing prevent meals from "ballooning" in aircraft ovens?
PA engineered castellated sealing profiles that vent air during heating, releasing pressure so the pack and meal hold their shape through reheating.
Can packaging materials be tested before buying a machine?
Yes. PA's Trial Facility validates trays, lidding films, and products on the actual machinery before any line investment, exactly as it did for Etihad.
