Ice Cream Tub: Preservation, Materials, and Design

The Ice Cream Tub: A World of Options for Preservation and Presentation

Common Materials in Ice Cream Tub Manufacturing

Cardboard and Paperboard

• Cardboard with PE/PLA coating: To ensure impermeability and resistance to moisture and fat from the ice cream, cardboard tubs usually have an internal coating. Traditionally, polyethylene (PE) has been used, a plastic that, although effective, makes recycling difficult. Recently, polylactic acid (PLA), a bioplastic derived from renewable resources like corn starch, has gained ground as a more sustainable alternative, being compostable under industrial conditions.
• Kraft Cardboard: Valued for its natural and rustic aesthetic, kraft cardboard, often unbleached, conveys an image of sustainability and authenticity. Like other cardboards, it requires an inner lining to be suitable for ice cream.
• Bleached Paperboard: Offers a smooth, bright surface ideal for high-quality designs and vibrant colors, allowing for sophisticated branding.

Plastic

• Polypropylene (PP): It is one of the most common plastics for ice cream tubs, especially larger ones. It is lightweight, resistant to low temperatures, has good rigidity, and is suitable for food contact. Furthermore, it is recyclable in many places. For a deeper dive into this material, you can consult the article "What is Polypropylene? Uses, Properties and Types of PP".
• PET (Polyethylene Terephthalate): Less common for the body of the tub, but used in transparent lids. It is lightweight, impact-resistant, and offers excellent product visibility. It is highly recyclable.
• Recycled plastics (rPET, rPP): The incorporation of post-consumer recycled (PCR) plastic in tub manufacturing is a growing trend to reduce reliance on virgin plastics and improve circularity.

Compostable and Biodegradable Materials

• Sugarcane Bagasse: A byproduct of the sugar industry, bagasse is a fibrous material that can be molded to create resistant, compostable, and biodegradable tubs.
• Corn Starch (PLA): As mentioned, PLA is not only used as a coating but can also be used to manufacture entire tubs, offering a compostable alternative to traditional plastics.

Design and Functionality: Beyond the Material

• HermeticityPrevents ice crystal formation and odor absorption.
• Thermal InsulationMaintains ice cream temperature and texture longer.
• Structural StrengthWithstands stacking and transport without deformation.
• Ease of OpeningA well-designed lid that is easy to open and close.

Shapes and Sizes

Lids and Closures

• Press-fit lids: Common on cardboard and plastic tubs, they offer a good seal and are reusable.
• Heat-sealed lids: Used in some formats for a tamper-evident and maximum freshness seal, often with an additional press-fit plastic lid for subsequent use.
• Dome lids: Ideal for ice cream with toppings or decorations, as they allow extra space without crushing the contents.

Customization and Branding on the Ice Cream Tub

Printing and Finishes

• Offset printing: Ideal for large volumes and high-quality designs, with vibrant colors and fine details.
• Digital printing: Suitable for shorter runs, prototypes, or designs requiring variable personalization. Offers flexibility and speed.
• Labeling: Allows pre-printed labels to be applied to standard tubs, a flexible option for small batches or market tests.
• Special finishes: Matte, glossy, metallic, or textured can add a premium touch and differentiate the product.

Key Design Elements

1. Logo and brand: Clear and prominently visible, reinforcing brand identity.
2. Product information: Flavor, ingredients, allergens, expiration date, and nutritional facts.
3. Graphic elements: Illustrations, photographs of the ice cream or ingredients, evoking flavor and quality.
4. Brand message: Slogans, brand history, or key values, conveying an emotional connection.

Sustainability and the Environment

Ecological Options

Certifications and Regulations

Common Mistakes When Choosing or Designing Ice Cream Tubs

• Underestimating the importance of insulation: A poorly insulated tub can lead to ice crystal formation and loss of the ice cream's original texture.
• Ignoring the lid's airtightness: A deficient seal allows air and odors to enter, affecting the product's flavor and shelf life.
• Prioritizing low cost over quality: Choosing the cheapest material can result in fragile, leaky tubs that do not adequately protect the product.
• Poorly legible or saturated design: Overloaded packaging with information or an unclear design can confuse the consumer and dilute the brand message.
• Not considering logistics: The shape and size of the tub should optimize freezer space, transport, and storage.
• Neglecting sustainability: In today's market, the lack of sustainable options can be a decisive factor for many consumers.

The Future of Ice Cream Tubs

• More advanced materials: Development of second-generation bioplastics and compostable materials with better performance and lower impact.
• Smart designs: Tubs with temperature indicators, compartments for toppings, or integrated spoons.
• Reuse and refill: Business models based on returnable tubs or ice cream refill stations.
• Minimalism and transparency: Designs that prioritize ice cream quality with clean, simple packaging that sometimes allows the product to be seen.

Frequently Asked Questions

What type of material is best to prevent ice cream from crystallizing?

Materials with good thermal insulation and, above all, a lid that provides an airtight seal are essential. Cardboard with PE/PLA coating and well-sealed polypropylene (PP) are effective options, as they minimize air entry and temperature fluctuations that cause crystallization.

Are cardboard tubs always ecological?

Not necessarily. Although cardboard is a renewable material, its sustainability depends on the type of internal coating used to make it waterproof. Cardboard tubs with traditional polyethylene (PE) coating are more difficult to recycle. More ecological options use PLA coatings or are "plastic-free," and should have certifications such as FSC or compostability.

Can small ice cream tubs be customized for events?

Yes, ice cream tubs are highly customizable. For events or small runs, digital printing or labeling are flexible options that allow for logos, dates, or specific designs. For larger volumes, offset printing offers superior quality.

What capacity do the most common ice cream tubs have?

Capacities vary widely. Individual tubs usually hold between 80 ml and 150 ml. Medium formats can range from 250 ml to 500 ml, and family or sharing formats go from 1 liter up to 2 liters or more. For the professional sector, there are tubs of several liters.

How does the shape of the tub influence the consumer experience?

The shape influences ease of storage, comfort when holding, and ice cream extraction. Round tubs are traditional and easy to serve, while square or oval tubs can optimize freezer space. Ergonomic design and a mouth wide enough for a spoon are details that enhance the experience.