Oven tray warping and leaking are a problem of correctly matching the tray and seal with how it is heated when cooking. The good news is that most are easy to avoid once you know what you’re looking for.
1) Wrong material for the job
Some trays that are ‘ovenable’ do not all cook the same way. It can actually happen sooner than one thinks with certain plastics, which may plastic-soften, especially in the case of somewhat longer cooking time or stronger fan oven heat.
Avoid it: Check the temperature and time rating of your tray for what you are going to cook, not just a headline number. For Ovenable Trays, visit //www.southerncrosspackaging.com/ovenable-trays
2) Uneven support and hotspots
If a tray is placed straight on an oven shelf, it can droop between gaps. Hotspots (or a tray placed too close to the heat) can lead to this sort of distortion and stress on seals.
Avoid it: bake on a level cooking sheet, and comply with dish shelf settings.
3) Seal and lidding films
The seal is the most common place for a leak to begin. If the wrong lidding film is used, or if there are seal strength issues, perhaps due to an inconsistent sealing temperature/pressure profile, then steam generated inside a tray can bubble its way up and your application fails.
Avoid it: use the film intended for that type of tray, verify sealing parameters and run regular seal checks.
4) Overfilling and steam pressure
Sauces and high moisture foods, or overfilling the trays, will produce more steam and pressure than most weak seals can prevent from blowing open.
Avoid it: stick to fill lines, use venting solutions if required and test worst-case articles.
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