The Future of Mining Sample Storage: Innovations in Core Tray Design

Mining is one of the oldest industries on Earth, yet it remains one of the most technologically dynamic. From exploration to extraction, modern mining is about accuracy, efficiency, and sustainability. But there is a simple piece of equipment that often gets overlooked despite its massive impact on project outcomes: the core tray.

A core tray is not just a box. It is the guardian of geological data, the silent partner of geologists, and the foundation of multi-million-dollar exploration projects. As global demand for minerals like copper, lithium, and rare earths accelerates, the importance of reliable and innovative core tray design has never been greater.

At PCT Plastic Core Trays, we have witnessed first-hand how mining companies worldwide are rethinking sample storage. Let’s explore where the industry has been, where it’s going, and why the future of mining depends on innovations in core tray design.

Why Core Trays Are the Backbone of Exploration

Every drill run brings up a physical record of the Earth’s geology. These samples — whether core or chips — are irreplaceable. Once disturbed, lost, or contaminated, the data they contain is gone forever. That is why core trays are more than storage: they are a chain of custody for geoscientific knowledge.

Poor storage can:

• Lead to core breakage or loss, jeopardising analysis.

• Cause contamination, making lab results unreliable.

• Delay projects with logistical inefficiencies.

• Increase safety risks for handlers through poor stacking or heavy lifting.

Choosing the right tray design is therefore not a minor operational detail — it is a strategic decision.

From Wood and Cardboard to Plastic: The Evolution of Core Storage

For decades, mining relied on wooden boxes or waxed cardboard trays.

• Wooden boxes were strong but extremely heavy, prone to splintering, and vulnerable to termites and rot. They were reliable in cold regions like Canada and Mongolia but hazardous to move in bulk.

• Wax cardboard trays were lighter and cheaper but lacked durability. They warped in wet conditions, collapsed under heavy cores, and deformed when stacked.

These limitations pushed the industry to look for better options. The turning point came with injection-moulded plastic core trays. Unlike their predecessors, these trays combined strength, lightness, durability, and resistance to water, UV, and chemicals.

Plastic trays also allowed for design features — safe stacking systems, drainage channels, ergonomic grip bars — that older materials could not achieve.

Today, plastic is the global standard. And at PCT Plastic Core Trays, we’re pushing it further by integrating sustainability and smart technologies into every tray.

Sustainability: A Driving Force in Mining Sample Storage

The global mining industry is under intense pressure to reduce its carbon footprint. Investors, governments, and communities demand greener supply chains. That responsibility extends to even the smallest components — including core trays.

At PCT, sustainability is not an afterthought. It is part of our DNA.

• We recycle 8,900 tons of plastic annually, preventing waste from polluting the environment.

• Our 7.3 MW solar power plant provides renewable energy for production, generating enough electricity to power 2,500 households.

• Our trays are designed for long life cycles — often lasting 30–40 years outdoors and virtually a lifetime indoors — reducing replacement demand.

By integrating plastic recycling and renewable energy into manufacturing, we provide mining companies with storage solutions that support their ESG commitments.

Modern Core Tray Features That Redefine Efficiency

Today’s geologists expect core trays to do more than just “hold samples.” Modern plastic core trays include features that directly improve field efficiency, data quality, and worker safety:

• UV Stability: Trays can be left outside for years without degrading under sunlight.

• Impact Resistance: Strong enough to withstand long-haul trucking on rough terrain.

• Safe Stacking Systems: Trays interlock securely, reducing the risk of accidents in warehouses and field sheds.

• Drainage Holes: Prevent water logging in wet climates and allow samples to dry evenly.

• Roller-Racking Friendly: Smooth bases for easy movement in core sheds.

• RFID & QR Integration: Digital identity embedded in trays for seamless tracking and inventory management.

• Integrated Stencils: Tru Identiti™-style markings for automated core imagery and labelling systems.

These innovations reduce human error, cut operational costs, and enhance the accuracy of geological data.

The Technical Case: Why HQ Trays Dominate

When it comes to global drilling programs, HQ trays are the benchmark. Their HQ-Size-4 (49–64 mm core diameter, 4 × 1 m capacity, 107 × 34 × 8 cm dimensions) configuration is optimised for both storage and transport.

• Large enough to hold significant core lengths.

• Compact enough for easy handling in the field.

• Designed to nest when empty and stack when full, maximising space.

With global demand for HQ-size drilling increasing, HQ trays represent the balance of technical performance, logistics efficiency, and safety.

Field Durability in Harsh Environments

Mining happens in some of the most extreme conditions on Earth — the deserts of Western Australia, the Arctic tundra of Canada, the tropical humidity of Indonesia, and the high altitudes of South America.

A modern HQ tray must withstand:

• Temperature extremes: from freezing tundras to 45°C desert heat.

• Chemical splashes: drilling fluids, oils, and corrosive materials.

• Heavy handling: forklifts, trucks, and manual lifting.

At PCT, our trays are engineered to survive these challenges. By resisting UV damage, impact stress, and chemical wear, they ensure sample integrity from drill site to laboratory.

Global Mining Demand & Sample Storage Needs

The future of mining will be driven by demand for key resources:

• Copper: essential for renewable energy, power grids, and EVs. Chile and Peru remain global leaders.

• Lithium: critical for batteries. Australia, Argentina, and Chile form the “lithium triangle.”

• Cobalt: 70% comes from the Democratic Republic of Congo, mostly as a byproduct of copper.

• Nickel: Indonesia is ramping up production to feed EV battery markets.

• Gold: Australia, China, Russia, and Ghana dominate supply.

Each of these industries depends on secure core and chip samples. With exploration expanding worldwide, demand for durable core trays will only increase.

Future Innovations in Core Tray Design

Looking ahead, the future of mining sample storage lies in smarter, greener, and safer trays. Key trends include:

1. Digital Integration
   RFID, barcoding, and cloud-linked tray IDs will enable automated inventory management and reduce human error.

2. Circular Economy
   End-of-life trays will be recycled back into production, closing the loop in sustainable manufacturing.

3. Next-Generation Plastics
   Lightweight, high-strength composites will further reduce logistics costs while maintaining durability.

4. Ergonomic Design
   Trays will feature improved grip systems, modular dividers, and safer stacking methods to reduce worker injuries.

5. Automation Compatibility
   As mines adopt automated warehouses and AI-driven geological analysis, trays will need to integrate seamlessly into digital workflows.

Why PCT Plastic Core Trays Are Setting the Global Standard

At PCT Plastic Core Trays, we are not just manufacturers — we are partners in mining progress.

• High Capacity: 3.2 million trays annually, scalable to 10 million.

• Fast Shipping: Same-day dispatch to prevent costly project delays.

• Global Reach: Exporting to 44 countries across every continent.

• Eco-Leadership: Solar-powered production and 100% recyclable plastic.

• Field-Tested Reliability: Trusted by geologists and drilling contractors worldwide.

Our mission is simple: to deliver durable, sustainable, and innovative storage solutions that support exploration companies in shaping the future of mining.

Conclusion: Innovation for a Sustainable Future

Mining will always evolve — from exploration technologies to digital twins of ore bodies — but one constant remains: the need for reliable sample storage.

The future of core tray design is not only about durability but also about sustainability and digital transformation. By integrating recycled materials, renewable energy, and smart features, PCT Plastic Core Trays is setting a new benchmark for the industry.

Every tray is a promise: to protect geological knowledge, to support efficient operations, and to contribute to a greener mining future.