Produce, Retail Display, and Kitting
Produce and agricultural packing
The open top allows for ventilation and inspection, while the top ledges provide a flat surface to stack multiple loaded trays on a pallet without crushing the contents.
Retail-ready shelf displays
Products remain visible and accessible to shoppers. The top ledges offer an upward-facing surface for branding, pricing, or promotional graphics.
Internal WIP and kitting
The integrated hand holes and double-wall ends make this tray easy for operators to carry heavy parts or assemblies between workstations.
Bakery and fresh food transport
The open center allows heat and moisture to escape, while the ledges provide the stacking strength needed for multi-tier delivery racks.
Retail, Distribution, and Industrial Handling
Retail merchandising
Store staff can lift and position these trays directly onto shelves. The locking structure keeps the tray rigid during repeated handling.
Food distribution
For bakery or fresh food distribution, the tray balances airflow with the structural integrity needed for palletized transport.
Industrial parts handling
Moving heavy components between assembly stations requires strong handles and the ability to stack trays without crushing the parts inside.
When to Compare Simpler Trays or Enclosed Shippers
Standard roll-end trays
If vertical stacking strength is not a primary concern, a standard roll-end tray without top ledges offers a simpler folding sequence and uses less corrugated board.
Fully enclosed shippers
This tray is open at the top and does not seal. If the product will be shipped individually through a parcel network, compare it to a fully enclosed mailer or standard shipping box.
Board Thickness, Ledge Width, and Assembly Planning
Board thickness and flute profile
An E-flute board works well for lighter retail displays, while heavier produce or industrial parts may require a thicker B or C-flute. Changing the board thickness requires adjusting the locking slots in the template so the tabs do not bind during assembly.
Ledge width
The width of the top ledge can be adjusted. A wider ledge increases stacking stability and branding space, while a narrower ledge provides a larger opening for product access.
Assembly labor
This tray requires a multi-step manual folding sequence. It is designed for hand-packing stations rather than automated folder-gluer lines.
Hand hole placement and sizing
Decide whether the cutouts need to accommodate gloved hands or if they should be removed entirely for automated lifting equipment.
Adjusting Handles, Ledges, and Locking Tabs
Hand hole sizing
The cutouts on the end walls can be resized to fit specific handling needs or removed entirely if carrying handles are not required.
Bench ledge width
The top horizontal panels can be widened to increase the stacking surface or narrowed to maximize the top opening for product access.
Tuck tongue depth
The locking tabs that secure the top ledges can be extended for a tighter hold if the tray will undergo rough handling.
Packing details
Flat delivery and storage footprint
Because the inner walls and top ledges are attached to the main body, the unfolded flat blank is relatively large. This may require a larger pallet footprint for storing the unassembled trays.
Additional notes
Print surfaces on the top ledge
The horizontal top ledges provide a prominent surface for branding, pricing, or handling instructions that remains readable even when the trays are stacked on a pallet.
FAQs
Does this tray require tape or glue to stay together?
No, it uses a series of locking tabs. The inner width walls lock into the base, and the top ledges tuck securely into the side walls.
Can this tray be erected on automated packing lines?
This specific design relies on a multi-step manual folding sequence. It is generally erected by hand at a packing station.
How do the top ledges improve stacking?
The horizontal ledges provide a flat resting surface for the tray above it. Because they lock into the end walls, they also prevent the long sides of the tray from bowing outward under vertical weight.
Can the hand holes tear under heavy loads?
The hand holes are cut through double-thick corrugated board on the ends of the tray, which provides extra reinforcement. For extremely heavy goods, a heavier board grade can be specified.
Can the width of the top ledge be changed?
Yes. The ledge can be widened for more stacking surface and branding area, or narrowed to provide a larger opening for product access.
What happens if we use a thicker corrugated board?
Thicker flutes improve stacking strength, but the locking slots for the top ledges and base tabs must be widened in the template to prevent the board from binding during assembly.
Is this tray suitable for parcel shipping?
No, the open top and manual locks are designed for palletized transport and retail display. Parcel shipping requires a fully enclosed outer box.
How are the top ledges secured in place?
The ends of the top ledges feature tuck tongues that fold down and lock into receiving slots on the top edges of the double-wall ends.
