Metal cans, while boasting excellent barrier properties, raise concerns about leaching and environmental impacts. This study explored plastic trays, a potential alternative for canned food packaging. First we delved into the plastic tray’s characteristics, including its composition and permeability to oxygen and water vapor. Secondly, we conducted a comparison between the newly introduced plastic packaging and traditional metal cans, focusing on their interactions with food during the sterilization process and their effects on the quality of Tunisian pea sauce. The composition analysis revealed that the plastic tray was composed of polypropylene (PP) (with a single endothermic peak at 168 °C), while the film was found to have a mixture of PP internally and polyethylene terephthalate (PET) externally (with two endothermic peaks at 161.96 °C and 243.81 °C). Plastic trays showed good results in water vapor permeability (0.832 g/m².d) but exhibited higher oxygen permeability (190 g/m².d), raising oxidation concerns. Migration testing confirmed plastic packaging safety (<10 mg/dm²), while some simulants exceeded limits in metal cans. pH levels remained consistent between both packaging types, but varied significantly over a 28-day storage. Total Volatile Basic Nitrogen (TVBN) levels differed significantly between plastic and metal packaging, with notable variations observed over time with maximums of 0.3 mg/100 g for plastic trays and 0.17 mg/100 g for metal cans. Sensory evaluation revealed that tasters were adept at differentiating between canned pea sauce in plastic trays and metal cans (83%, 10/12), with taste and color exhibiting significant differences (p < 0.05). This underlines the impact of packaging material on canned food quality and consumer preference, with minimal influence on other sensory aspects. This data empowers manufacturers to make informed packaging decisions for a diverse range of canned foods.