Copacol launches air fryer-ready cellulose tray

Brazilian food producer Copacol has introduced a cellulose-based packaging tray for seasoned frozen chicken that can move directly from the freezer into an air fryer, combining product protection, preparation convenience and a fibre-based material structure.

The company says the tray is made entirely from cellulose and contains no plastic. It is designed to remain with the product throughout freezing, storage and cooking, eliminating the need for consumers to transfer the chicken into a separate container before preparation.

Packaging becomes part of the cooking process

The format has been developed specifically around the growing use of air fryers in Brazilian households. Consumers can remove the packaged product from the freezer and place the tray directly into the appliance, reducing handling and simplifying meal preparation.

Copacol also highlights easier cleaning as a consumer benefit, since the tray helps prevent food residues and grease from coming into direct contact with the air fryer basket.

Cellulose replaces conventional plastic tray formats

According to the company, the packaging is 100% recyclable and biodegradable and is expected to decompose within approximately 75 days under suitable conditions.

The use of cellulose is intended to reduce the environmental impact associated with conventional plastic trays while retaining the performance required for frozen storage and cooking.

Format developed for multiple chicken cuts

The new packaging is suitable for approximately 500 g portions and can be used for chicken breast fillets, drumsticks, mid-wings, wing tips and other cuts. Each pack typically contains between six and eight pieces depending on the product.

The format also supports Copacol’s positioning around seasoned products prepared with natural ingredients, creating a complete ready-to-cook proposition rather than simply replacing the packaging material.

Convenience influences food packaging development

The launch illustrates how changes in kitchen appliances are beginning to influence packaging design. Air fryers have become widely used for faster meal preparation, creating demand for food formats and packs that can integrate directly with this cooking method.

Packaging that remains with the product during heating can reduce preparation steps, but it must also withstand temperature changes from frozen storage to cooking while maintaining structural integrity and food-contact safety.

Copacol presented the concept at APAS 2026

The company showcased the packaging at APAS 2026 in São Paulo, using the event to demonstrate the complete preparation experience to retailers and consumers.

Copacol plans to expand distribution of the air fryer-ready chicken range across Brazil, positioning the packaging as part of a broader combination of convenience, food quality and environmental responsibility.

Fibre trays move into more demanding applications

The development reflects a wider trend towards fibre-based trays capable of performing beyond conventional foodservice applications. Manufacturers are increasingly designing cellulose and paperboard formats that can withstand freezing, heating and direct food contact.

For food brands, this creates opportunities to replace plastic while also adding functionality. Copacol’s solution demonstrates how packaging material innovation can be combined with changing consumer behaviour to make the pack part of the product preparation experience itself.