Retail Display and Kitting Applications
Retail shelf displays
The bench panels frame the product and provide a clean top edge, making it an excellent choice for shelf-ready displays where products need to be visible but protected from the weight of the tray above.
Produce and agricultural packing
For agricultural goods, the reinforced short ends and stacking ledges transfer vertical weight efficiently, preventing the tray walls from crushing under pallet loads while allowing ventilation.
Heavy kitted components
Industrial parts and heavy kits benefit from the rigid corners and bench supports, which keep the tray stable during transport without requiring a sealed top.
Internal work-in-progress (WIP) trays
Manufacturing facilities use bench-support trays to move parts between stations. The open top allows quick access, while the ledges permit safe stacking on carts or shelving.
Retail, Produce, and In-Plant Logistics
Big-box retail and club stores
Buyers supplying big-box retailers use this style to eliminate the need for store staff to cut open boxes. The tray arrives ready for the shelf, with the bench ledges framing the merchandise.
Agricultural and fresh produce
Farms and distributors use stacking trays to move delicate produce. The bench ledges keep the weight off the fruit or vegetables below, while the open top allows for cooling and inspection.
Industrial assembly lines
Operations managers use these trays to organize parts for assembly. The glue-free construction means they can be stored flat and erected on demand right at the workstation.
When to Consider a Different Tray Style
High-speed automated packing
If your packing line relies on automated folder-gluers or tray erectors, a standard glued tray or machine-erected design is usually a better fit. This template is designed for manual assembly.
Individual parcel shipping
Because the top is open, this tray cannot be shipped individually through courier networks without being placed inside a separate master carton.
Board, Flute, and Assembly Planning
Manual assembly labor allocation
This tray requires manual folding and locking at the pack bench. Fulfillment teams should account for the time needed to engage the base locks and tuck the bench tongues.
Board flute and slot width
The locking slots are precisely sized to the board thickness. If you change from a thin E-flute to a thicker B-flute or C-flute for extra stacking strength, the slot widths must be recalculated to prevent the tabs from binding or tearing during assembly.
Bench width and product clearance
The width of the horizontal bench panels dictates how much of the product is covered. You must balance the need for a wide stacking surface against the need for product visibility and access.
Print surface allocation on the bench
The bench panels fold inward from the short walls, meaning their visible top surface can be printed along with the exterior of the tray. This provides a highly visible area for branding or instructions.
Adjusting the Bench and Tray Dimensions
Bench width adjustments
The width of the horizontal bench panels can be adjusted. A wider bench provides more stacking surface and branding area, while a narrower bench increases the open display area for the product.
Long-wall top flange width
The narrow flanges that fold over the top of the long walls can be widened or narrowed to change the stiffness of the side walls and the visual framing of the tray.
Base lock tongue length
The tongues that secure the long walls to the base can be adjusted in length. Longer tongues provide a more secure lock but may require more effort to engage during manual assembly.
Packing details
Print panel visibility on the bench ledge
The bench panels offer a highly visible horizontal surface for logos, instructions, or retail branding that faces the consumer when the tray is placed below eye level.
Additional notes
Production route and flatbed die-cutting
Due to the complex locking tabs and slots required for the bench supports, this tray must be produced using flatbed die-cutting equipment rather than a standard rotary slotter.
FAQs
Does this tray require glue or tape?
No. The tray assembles entirely using mechanical locks. The base is secured by side-flap tongues, and the top bench is secured by tuck tabs.
Can this tray be erected by automated machinery?
Generally, no. The complex folding sequence for the bench supports and tuck tabs is designed for manual assembly at a packing station.
How much weight can the bench supports hold?
The vertical compression strength depends entirely on the chosen corrugated board grade and flute profile. The bench design improves load transfer, but exact limits should be verified through physical testing with your product.
Can the bench panels be printed?
Yes. Because the bench panels fold inward from the short walls, their visible top surface can be printed along with the exterior of the tray.
Can I make the bench wider to cover more of the product?
Yes. The bench width is an adjustable parameter. However, extending it too far may require changes to the tuck tab geometry to maintain structural stability.
Is this tray suitable for ecommerce parcel shipping?
Not on its own. The open top leaves the contents exposed. For parcel networks, this tray must be packed inside a closed outer shipping box.
Can I use a double-wall board for this tray?
Double-wall board can make the manual folding process difficult and may cause the locking tabs to bind. If heavy board is required, the slot widths and crease allowances must be carefully adjusted and tested.
How are the long walls secured to the base?
The long walls have side flaps that fold inward. These flaps feature locking tongues that engage with receiver slots located along the base perimeter, holding the walls upright.
