ProAmpac develops fibre tray for Circle K hot food launch

ProAmpac has developed a custom fibre-based tray for Circle K’s new Flamin’ Hot Boneless Chicken Wings, combining structural design, grease resistance and heat-retention performance for hot food merchandising.

The product was launched by Circle K in partnership with PepsiCo/Frito-Lay, with the packaging designed specifically around the recipe, portion size and operational requirements of heated retail displays.

Rather than adapting a standard foodservice tray, ProAmpac worked with the retailer to address several challenges associated with holding prepared chicken at serving temperature while maintaining product quality and visual appeal.

Heat retention and moisture control drive the design

Hot food packaging must balance several competing requirements. The pack needs to retain heat while limiting moisture loss, but it must also avoid creating excessive condensation that can affect texture and presentation.

ProAmpac says the new tray was engineered to help keep the chicken hot and moist for longer while maintaining the structural performance required in heated display cabinets.

The format is also designed to improve product visibility, allowing consumers to see the food more clearly before purchase.

Grease resistance supports cleaner presentation

Grease management was another important requirement for the project.

Fried and coated foods can place significant demands on fibre-based packaging, particularly during extended hot-hold periods when oils may migrate into the substrate.

The custom tray incorporates enhanced grease resistance intended to maintain a cleaner appearance throughout the merchandising period and reduce visible staining around the package.

Packaging design adapted to the product itself

The project highlights the growing importance of designing foodservice packaging around specific product characteristics rather than relying exclusively on standard formats.

Portion size, surface coating, moisture content, serving temperature and anticipated hold time can all influence packaging performance.

By tailoring the tray to the Flamin’ Hot chicken product, ProAmpac aimed to optimise both operational performance and the consumer eating experience.

Branding remains important in hot-hold displays

The packaging also incorporates bold graphics aligned with the Flamin’ Hot visual identity, helping the product stand out within Circle K’s heated food cabinets.

For convenience retailers, hot food packaging increasingly needs to perform as both a functional container and a point-of-sale communication tool.

Clear visibility, recognisable branding and a clean presentation can therefore be as important as thermal and barrier performance when products are displayed for immediate purchase.

Fibre-based food-to-go formats continue to expand

ProAmpac has been expanding its fibre-based foodservice portfolio for hot applications, including packaging designed for heated cabinets and extended holding periods.

The company is also preparing several fibre-based formats for the LUNCH! 2026 trade show, including Hot Hold Box, Hot HandRap and Hot Hold Carton solutions, which it says can support hot-hold times of up to four hours.

The Circle K project demonstrates how fibre packaging is moving into increasingly demanding food-to-go applications where heat, grease, moisture and shelf presentation must be managed simultaneously.

Customisation becomes part of foodservice packaging strategy

As convenience stores and foodservice operators expand their prepared-food ranges, packaging suppliers are increasingly being asked to support product development from an earlier stage.

Material science, structural design and operational testing can determine whether a new menu item performs consistently from preparation through merchandising and consumption.

The ProAmpac and Circle K collaboration shows how customised packaging can become part of the product launch itself, supporting both food quality and retail presentation rather than functioning only as a final containment step.