In-flight meals have come a long way from foil trays, bland taste, and ambiguous preparation. Today, airlines are investing in personalized menus designed by celebrity chefs, AI-driven catering logistics, and packaging that can withstand sterilization processes, changes in altitude, pressure variations, and turbulence.
New Challenges and Trends in Airline Catering
Recent years marked a certain shift in the airline catering industry. In particular, the rise of personalization is one of the most significant trends. Passengers can now pre-order from extensive menus, with some international carriers offering dozens of premium choices even in economy. This move towards customization, supported by AI-based menu planning, accommodates a vast array of dietary, religious, and health needs that were once an afterthought.
Health, safety, and freshness have become the new standards across all cabins. Airlines are increasingly offering plant-based, gluten-free, and other wellness-focused meals, all while rotating menus seasonally to ensure variety and quality. Looking ahead to 2026, innovations such as advanced galley technology promise to revolutionize service. These advanced systems will allow for on-demand chilling and heating, enabling true restaurant-quality experience for premium passengers.
Sustainability has also moved to the forefront, influencing everything from sourcing to packaging. The focus is not just on pleasing environmentally conscious travelers but also on the practical benefits of weight and waste reduction, which directly impact fuel costs and operational efficiency. Industry leaders like Lufthansa, ANA, Emirates, and Etihad are pioneering many of these changes, from using AI to track and reduce food waste to transitioning toward lighter, more sustainable meal containers.
Why Packaging Is the Hidden Hero
Beyond the menu itself, one of the least visible yet most vital component of in-flight dining is the packaging that holds it all together. The journey of an in-flight meal begins long before takeoff, and its container must be highly engineered. Packaging must endure retort sterilization, a process involving high-pressure steam at temperatures up to 120°C to ensure food safety and a long shelf life without refrigeration.
It also needs to preserve the freshness and separation of ingredients during long-haul storage, be lightweight to save fuel, and remain durable enough to withstand the rigors of transit and turbulence. Finally, it has to be compatible with various reheating systems and still present the food attractively once it reaches the passenger’s tray table. A meal that looks unappealing is a failure, no matter how good the recipe is.
The MCP CPET S&R Tray – Function Meets Fine Dining
One recent innovation addressing these challenges is MCP’s CPET S&R tray, a winner of the prestigious 2025 WorldStar Award from the World Packaging Organization (WPO). This CPET tray was specifically engineered for the demands of ready meals and airline catering. It handles retort processing, maintaining its structure and the integrity of its hermetic seal even under extreme heat and pressure. It is also compatible with microwave and industrial ovens at temperatures up to 220°C and is resistant to cracking and deformation during thermal cycles.
The design’s real differentiator, however, is its 3-compartment layout with a dedicated sauce compartment. This was a significant engineering feat, as smaller compartments are often the first to fail under stress. By solving this, the tray allows for more complex and appealing meals where sauces can be kept separate until served, preserving texture and flavor.
All MCP trays offer multiple advantages for airline catering. They are durable, microwavable, and oven safe. Made from a single material, CPET, they are fully recyclable and can include up to 70% PCR content. Their reduced thickness lowers plastic use, weight, and carbon footprint, without compromising durability or dimensional stability. The trays come in various sizes and internal layouts, including non-pigmented versions.
The Next Course in Airline Dining
As the airline industry moves further into the new era, the foundational elements of the dining experience become even more critical. All of this advanced technology ultimately relies on a solid, well-engineered container to deliver the final product. Innovations in packaging, like the S&R tray, are the unsung heroes that ensure the chef’s vision and the airline’s investment reach the passenger intact.