Interactive 3D

1 / 3

EVC41049

Corrugated Notch-Lock Tray

Available in a wide range of custom configurations & material selection.
Order 1 sample. Or order 100K+ units. Or anything in between.
Affordable delivery across North America.
Design support, warehousing, testing, assembly available.
Widest machinery capability in America via 30+ specialist partner plants.

Get pricing

Free white-glove consultations. Blazing-fast response time. Fast quotes.

Product details

Top highlights

Tape-free manual assembly using four corner notch locks
Delivered flat to maximize pallet density and storage space
Open-top design relies on an outer carton or shrink wrap for parcel shipping

About this product

The EVC41049 is a one-piece corrugated tray that assembles entirely without tape or glue. Delivered flat, it uses a hook-and-slit locking mechanism at each corner to create a stable, open-top container for parts kitting, internal transport, or retail display.

Because the corner flaps wrap around the exterior of the side walls to lock into place, this tray provides excellent rigidity for its weight, though it relies on manual assembly at the packing station.

Common uses

Parts kitting on manufacturing floors
Bakery and produce transport
Base trays for shrink-wrapped multi-packs
Shelf-ready retail displays

Get a quote

Share what you know. We'll take it from there. Or email us at info@herculeindustrial.com

Describe your project *

Approximate quantity *

Size if known

Files or competing quote (optional)Drag files here or choose filesAdd drawings, photos, dielines, quotes, specs, or other useful files.Max 5 files, 25 MB total.

Name *

Email *

Phone

Optional

More details

You can skip this whole part, or open a section and answer only what you know.

Size and quantity

Detailed dimensions

Units US customary (inches)Metric

What do your dimensions describe?

Length

Width

Height

Size notes

Quantity notes

Materials and print

Material or strength preference

Add details for material or strength preference

Material or strength details

Print and artwork

Add details for print and artwork

Print, finish, or artwork details

Shipping or storage context

Custom changes or unusual needs

How will this tray mainly be used?

About how much weight will each tray hold?

Do you need custom printing on the outside of the tray?

Current box or specs

Do you have a current box, spec, or target sample?

Add details for do you have a current box, spec, or target sample?

Current box, known specs, or current problem

Destination ZIP or region

Company

Any deadline or timing constraint?

Practical Uses for the Notch-Lock Tray

Parts Kitting and Assembly Lines

The tape-free setup and open top make this tray very effective for organizing components on a manufacturing floor. Workers can quickly erect the tray, load parts, and move it between stations.

Shrink-Wrap Base Trays

For retail multi-packs or beverage distribution, the tray provides a rigid, squared base that holds products together before the final shrink-wrap film is applied.

Produce and Bakery Transport

When cut from appropriate moisture-resistant board, the open design allows for ventilation and easy access during short-distance transport or shelf stocking.

Internal Work-in-Progress Storage

Facilities that need temporary bins for sorting or holding semi-finished goods can use these trays to keep items organized without investing in permanent plastic totes.

Industry and Packing Environments

Manual Fulfillment Operations

Packing lines that want to eliminate tape guns and glue stations benefit from the mechanical locks, though the four-corner assembly does take dedicated operator handling.

Retail and Shelf-Ready Displays

The tray can transition directly to a retail shelf. However, because the corner flaps wrap around the outside, graphics should be planned carefully to account for the overlapping board.

Short-Distance Distribution

For local deliveries where pallets are shrink-wrapped and open tops are acceptable, this tray provides a lightweight containment option that avoids the cost of fully enclosed boxes.

When to Consider a Different Tray Style

High-Speed Automated Packing

If your line uses automated tray erectors or folder-gluers, a machine-erected glued tray or a common four-corner glued tray will be much faster than this manual notch-lock design.

Standalone Parcel Shipping

Because this tray has no lid, it is not designed to be shipped through courier networks on its own. If you need a fully enclosed shipper, compare this to a roll-end tuck-top mailer or a regular slotted box.

Board Thickness, Labor, and Sizing

Board Flute and Lock Clearance

The hook-and-slit mechanism is very sensitive to board thickness. E-flute (1.5mm) is a common starting point. If you need thicker B-flute or C-flute for heavier payloads, the lock dimensions should be widened so the tabs do not crush during assembly.

Print Panel Layout

The exterior side walls are partially covered by the corner flaps. If you need continuous, unbroken graphics across the entire side of the tray, a different corner construction may be necessary.

Packing Line Labor

While tape-free, the tray relies on an operator to fold and seat four separate locks. Evaluate whether this manual motion fits your packing speed goals compared to a pre-glued auto-bottom tray.

Outer Shipper Compatibility

If these trays will eventually be packed into a larger master carton for freight, the external dimensions of the assembled tray, including the slight bulge of the corner flaps, should be calculated to ensure a proper fit.

Adjusting the Lock and Tray Dimensions

Locking Tab Height and Width

The size of the male locking tab and the receiving slit can be adjusted to balance assembly speed with retention strength, depending on the board grade chosen.

Female Cut Clearance

The width of the receiving slit on the side walls can be widened to accommodate thicker flutes, ensuring the locking tab inserts smoothly without tearing the board.

Corner Flap Extension

The length of the corner flap that wraps around the side wall can be modified. A longer flap provides more gluing or locking surface area, while a shorter flap exposes more of the side wall for printing.

Packing details

Flat Delivery and Storage

These trays ship completely flat and nest efficiently on a pallet, making them an excellent choice for facilities with limited storage space for packaging materials.

Additional notes

Lock clearance and board thickness

Changing the flute profile directly impacts how the locks function. If the board is too thick for the cut slits, the packer will crush the tabs trying to force them in. Always verify the lock geometry when changing materials.

FAQs

Does this tray use tape or glue to stay together?

No. The tray relies entirely on mechanical notch locks at the four corners. The corner flaps wrap around the side walls and hook into pre-cut slits to hold the tray rigid.

Is this tray suitable for automated packing lines?

Generally, no. The specific motion needed to wrap the corner flaps and seat the locking tabs is designed for manual assembly at a packing station.

Can I use a heavy double-wall board for this tray?

Double-wall board is usually a poor fit for this specific lock style. The thick board makes the corner flaps too stiff to fold easily, and the locking tabs can become too tight to engage by hand. E-flute or B-flute are much better choices.

Can I ship this tray through the mail?

Not on its own. It is an open-top tray. To ship it via parcel courier, it should be placed inside an outer shipping carton or fitted with a secure lid.

How do the corner flaps affect custom printing?

Because the corner flaps wrap around the outside of the side walls, they will cover the ends of whatever graphics are printed on those side panels. Your artwork should be designed to accommodate this overlap.

Should I request a physical sample before ordering?

Yes. Because the notch locks depend heavily on friction and board thickness, testing a physical sample ensures the tray is easy for your team to assemble and holds together securely with your specific product.

Can these trays be stacked on top of each other?

The tray itself does not have a lid or stacking shoulders. Stacking is only possible if the product inside is rigid and flat enough to support the weight of the tray above it.

How are these trays delivered?

They are delivered completely flat. This maximizes the number of trays that can fit on a single pallet, reducing shipping costs and saving warehouse space.