Product and Kitting Uses for the Two-Height Tray
Shelf-Ready Retail Displays
The paired high walls provide a billboard for branding and help contain loose or stacked items, while the lower walls allow shoppers to easily see and remove the product.
Internal Kitting and Parts Picking
For assembly lines or fulfillment centers, the lower walls offer hand clearance for quick picking, making this a practical open-top bin for organizing components.
Work-in-Progress Component Storage
During manufacturing, these trays keep sub-assemblies organized. The high walls prevent parts from spilling off the back or front, while the low sides allow workers to retrieve items without reaching over a tall barrier.
Produce and Farm Stand Displays
For agricultural goods that need ventilation and visibility, the two-height design allows customers to inspect the produce while keeping the items contained on the shelf.
Retail and Warehouse Environments
Manual Packing Operations
This tray is a common choice for manual pack benches. It folds together quickly using mechanical locks, eliminating the need for tape dispensers or gluing equipment.
Fulfillment Centers and Warehouses
Operations managing active pick faces use these trays to organize small parts. The open access speeds up order fulfillment, while the flat delivery saves storage space before assembly.
Retail Merchandising
Brands preparing shelf-ready goods use the high walls for primary graphics and product information, relying on the low walls to remove barriers between the shopper and the item.
Situations That Point to Other Trays
Uniform Wall Height Needs
If your product requires equal containment on all four sides, or if you need to stack the trays directly on top of each other without a master carton, look at a standard four-wall tray like the FEFCO 0422.
Parcel Shipping and Enclosed Transit
This is an open-top tray. If the package will be shipped individually through a courier network, it needs an outer shipper or should be replaced with a fully enclosed mailer.
Board, Print, and Assembly Choices
Board Thickness and Lock Fit
The roll-over walls and locking tabs rely on precise clearances. Thicker board grades require wider double creases and slots, which should be prototyped to ensure the locks seat firmly without tearing.
Print Surface Visibility
Because the lower walls roll over into the interior of the tray, the outside print surface of the flat blank becomes visible on the inside of those walls. Discuss two-sided printing if you need branding on both the interior floor and the exterior high walls.
Wall Height Proportions
The difference between the high and low walls dictates both containment and access. Review the product dimensions to ensure the low walls do not expose too much of the item, risking spills during handling.
Outer Shipper Requirements
Since this tray cannot be shipped through parcel networks on its own, plan the dimensions of the master carton early. The tray dimensions must account for the internal clearance of the outer box.
Adjusting the Tray Dimensions
Adjusting the Low Wall Height
The height of the two lower roll-over walls can be adjusted independently of the high walls, allowing you to tune the tray for deeper containment or shallower access depending on the product.
Modifying the High Wall Profile
The two high walls can be extended to provide more branding space or better support for taller items, provided the overall blank size remains efficient for production.
Adjusting the Locking Tab Width
For heavier board grades or specific assembly needs, the width of the locking tabs and their receiving slots can be modified to ensure a tighter mechanical hold.
Packing details
Flat Delivery and Storage
These trays ship flat and offer excellent pallet density, minimizing storage space before they are needed on the packing floor.
Additional notes
Symmetric wall geometry and display orientation
While sometimes called a 'raised wall' tray, this template features two opposite high walls and two opposite low walls, rather than a single high back and a single low front.
FAQs
Does this tray require tape or glue?
The tray uses a roll-end locking mechanism, meaning it assembles without tape or adhesive. The lower side walls fold over the corner dust flaps and lock into slots in the base, holding the entire tray together mechanically.
Can I change the height of the low walls?
The height of the lower access walls can be adjusted during specification to expose more or less of the product, while the high walls remain at your specified height.
Can this tray be shipped through parcel networks?
Because it has an open top and paired low walls, it is designed for display, kitting, or palletized transport. For parcel shipping, it needs an outer master carton to protect the contents.
Where does the printing show on the assembled tray?
Standard outside printing will appear on the exterior of the high walls and the base. Because the lower walls roll over, the outside print will also show on the inside faces of those lower walls. If you need branding everywhere, two-sided printing is required.
What board grades work well for this tray?
Thinner grades like E-flute or B-flute are usually chosen because they allow the roll-over walls to fold cleanly and the tabs to lock securely. Thicker boards can cause the double creases to bind or the locks to pop open.
Is this tray suitable for automated assembly?
This specific roll-end structure is typically a manual-pack choice. It is not a native fit for standard linear folder-gluers.
How do I determine the right height for the lower walls?
The lower walls should be tall enough to keep the product from sliding out during handling, but low enough to allow easy hand clearance for picking or full visibility for retail display.
Can I stack these trays on a pallet?
Because of the open top and uneven wall heights, these trays are not designed to bear heavy vertical loads on their own. They should be stacked inside master cartons or on specialized racking.
