Custom Popcorn Trays

Sizing Around Cups and Tubs

Measure the base of your drinks cup, not the rim, because the cup sits in the hole by its lower part. A standard 16 oz cup has a base of around 60–65 mm, and a 22 oz cup is usually around 65–70 mm. We cut the hole a fraction larger so cups drop in easily but do not tip.

For a built-in popcorn scoop, think in terms of portion size. A small kids' portion fits a compartment of about 100 x 80 x 80 mm, while a medium cinema portion needs around 130 x 100 x 120 mm. If you use separate tubs, measure the tub base and height, and decide how much of the tub should sit inside the tray for stability.

The overall tray is then laid out so the weight is balanced. A drink is heavy and popcorn is light, so the handle or carry point sits closer to the drink.

If you sell several cup sizes, a hole sized for the largest cup with a flexible tabbed edge can hold smaller cups too. The tabs flex inwards to grip a narrower base, so one tray works across the menu.

Build a mock-up from plain card with your real cups and tubs before printing. Walk it from the counter to a seat with a full drink and see whether it tips or flexes. A few minutes of testing saves an expensive reprint. p4 The guide to measuring a product covers base diameters on tapered cups.

Board and Food Contact

Popcorn trays are usually made from 350–400 gsm folding board, or from thin E-flute corrugated board for larger trays carrying two drinks. The board must be stiff enough not to sag under a full cup. Food-contact grade board is available on request for trays where popcorn sits directly in the card.

Butter and oil can mark untreated board, so a grease-resistant coating on the inside of a built-in scoop helps keep the tray looking clean. If you serve heavily buttered popcorn, a separate tub or liner is the better choice.

For sweet or salted popcorn served without butter, plain food-contact board is usually enough, and it keeps the tray simple and economical. p2 Board weights are explained on the guide to board and card types.

Designs That Suit Cinemas and Parties

Classic red and white stripes remain a favourite for cinemas because they instantly say popcorn. Many venues add their logo on the front and a short message on the side, such as a reminder about membership or a loyalty offer. Children's venues choose bright cartoon graphics, games or puzzles printed on the tray so kids have something to look at before the film or between activities.

Event organisers often print the event name and sponsor logos, and some add a QR code linking to a feedback survey or a future booking page. Keep critical text away from the drink hole and the folds, where it can be hidden or distorted.

Film studios and distributors sometimes fund tie-in trays for big releases. If you run an independent cinema, ask your distributor whether promotional artwork is available, as it can make a short themed run worthwhile. p2 Cinemas with a classic stripe often match the tray to our red and white striped popcorn boxes.

Cinemas, Bowling Alleys and Fêtes

Independent cinemas and small cinema chains are the main buyers, along with bowling alleys, family entertainment centres and soft play venues. Children's party organisers use them for party food. Sports grounds, theatres and concert venues use them during intervals. School fairs and village fêtes use simple printed trays for snack stalls, and mobile popcorn caterers use them at weddings and corporate events.

Holiday parks and seaside attractions use them for family snack deals, and ice rinks and leisure centres serve hot popcorn and drinks to spectators in the same trays. p1 Sports grounds that serve nachos in the same tray can see our printed nacho trays for the food side.

Walk a Card Mock-Up From the Counter to a Seat

A popcorn tray is a balance problem before it is a print job. Cut a rough tray from plain card with the drink hole sized to your cup base, not the rim, load a full drink and a full tub, and walk it from the counter to a back-row seat. If it tips towards the drink, the carry point needs to move; if the hole grips too hard, the cup will not drop in on a busy Saturday. Send us the cup base diameter, the tub base and height, and the layout that survived the walk.

Say which cup sizes you sell, since a tabbed hole cut for the largest will hold the smaller ones too. The custom quote arrives by email within one working day with the minimum set per job, so a single-screen cinema can order what it needs.

The free proof shows the dieline with the cut-outs and the print positions. Production takes 4 to 7 working days after approval and the flat trays reach UK mainland addresses by free tracked delivery. Venues that fill popcorn into their own tubs usually order printed popcorn buckets in the same stripe to sit in the tray.