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EVC41051

Double-Wall Corrugated 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.

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Product details

Top highlights

Double walls on all four sides for rigidity
Friction-lock assembly holds without glue or tape
Clean rolled edges hide raw corrugated flutes

About this product

This roll-end corrugated tray features double-folded walls on all four sides, creating a rigid, open-top tray without the use of glue or tape. The inner panels roll over the corner dust flaps and lock securely into the base, providing clean, finished edges that hide the raw corrugated flutes.

Because it uses more board than a single-wall tray and requires manual assembly, it is typically chosen when presentation and stacking support are critical, such as for retail shelf displays, heavy component kitting, or premium unboxing inserts.

Common uses

Retail shelf displays
heavy industrial parts kitting
premium e-commerce inserts

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Retail Shelf Displays And Heavy Kitting

Retail Shelf Displays

The double-folded walls create a thick, clean top edge that hides the raw corrugated flutes. This gives the tray a finished look suitable for direct retail presentation, while the multi-layered walls resist bowing when loaded with dense products.

Heavy Component Kitting

For industrial or automotive parts, the four double walls provide strong stacking support and side-impact protection. The tray can hold heavy metal or machined components without the sides splaying outward.

Premium E-Commerce Inserts

When used inside a larger mailer or master shipper, this tray provides a rigid inner collar. It protects fragile items and provides a printable, clean-edged unboxing experience.

High-Density Storage Trays

For internal warehouse organization, the glue-free assembly allows trays to be stored flat and erected on demand. The double walls provide the durability needed for repeated handling and parts picking.

Manual Packing And Fulfillment Operations

Manual Packing Operations

This tray is delivered flat and erected by hand. The assembly sequence involves pre-breaking the creases, folding up the primary walls, and rolling the secondary walls over the corners to lock into the base. It is efficient for inbound freight but requires dedicated labor for repeat fulfillment.

Retail and Point-of-Purchase Merchandising

Brands looking to present products directly on shelves often choose this tray for its clean edges. The rolled top hides the corrugated fluting, offering a more polished appearance than a standard slotted tray.

Subscription and Premium Unboxing

When paired with an outer mailer, this tray acts as a sturdy, printable insert. It elevates the unboxing experience by framing the product with thick, finished walls while adding structural support to the outer package.

When To Compare Glued Or Single-Wall Trays

High-Speed Automated Fulfillment

Because this tray uses a complex sequence of 3D mechanical folds and friction locks, it is difficult to erect on standard linear folder-gluers. If your line relies on automated tray forming, a four-corner glued tray or a specialized machine-erected tray may be a better choice.

Material-Sensitive Repeat Programs

Doubling all four walls requires a large flat blank, increasing material usage compared to a single-wall tray. If high rigidity and clean edges are not strictly necessary, a common roll-end tray that only doubles two walls will reduce the material footprint.

Board Thickness And Print Surface Planning

Board Thickness And Flute Profile

This tray is sensitive to board caliper. It performs well in thin profiles like E-flute, which allows for crisp folding and tight locks. Heavier boards like C-flute or double-wall grades risk crease cracking on the outer rolls and may prevent the locking tabs from seating properly.

Inside And Outside Print Surfaces

Because the inner walls fold down from the outer walls, the interior walls and the exterior base share the same side of the flat corrugated sheet. This allows for efficient two-sided branding without requiring double-sided printing on the press.

Assembly Labor Planning

Since the tray relies on a multi-step friction-lock fold rather than glue, packing teams should account for the time required to erect each unit by hand. For high-volume runs, a pre-glued tray might be worth evaluating.

Outer Shipper Compatibility

As an open-top tray, this package cannot ship through parcel networks on its own. It should be sized to fit precisely within a master shipper or mailer if it will be used for e-commerce distribution.

Locking Tab And Clearance Adjustments

Locking Tab Clearances

The base slots and locking tabs should be precisely matched to the chosen board thickness. If the material changes, these clearances should be recalculated to ensure the tray stays locked under tension.

Double Crease Allowances

The top edges feature a double crease to accommodate the board rolling over itself. The distance between these creases can be adjusted based on the specific flute profile to prevent cracking or loose walls.

Hand Hole Additions

For easier carrying, hand holes can often be added to the outer walls. These cutouts should be placed carefully to avoid interfering with the double crease at the top edge or the locking tabs at the base.

Packing details

Parcel Shipping Limitations

This is an open-top tray, not a shipping box. It cannot be sent through parcel or courier networks on its own. It should be placed inside a master shipper, a mailer, or fitted with a custom lid.

Additional notes

Crease cracking risk

The top edges of the tray feature a double crease where the board rolls 180 degrees. If the board is too thick or the paper liners are brittle, this edge is susceptible to cracking.

FAQs

Does this tray need glue or tape?

No. The tray uses a mechanical friction-lock system. The inner walls roll over the corner dust flaps and feature small tabs that seat firmly into slots on the base panel.

Can this tray be machine-erected?

It is primarily designed for manual assembly. While specialized plunger-style tray formers can erect similar structures, it is generally not compatible with standard linear folder-gluers.

What board grades fit this tray?

Thin profiles like E-flute are often a better fit. The double creases require the board to fold over itself; thicker flutes like C-flute or double-wall board will likely crack under the stress and prevent the locks from seating properly.

How does printing work on the double walls?

The inner walls are extensions of the outer walls on the flat blank. This means the inside walls and the outside bottom of the tray are printed on the same side of the corrugated sheet, making it very efficient for custom branding.

Can I ship this tray through the mail?

Not on its own. It is an open-top tray without a lid or seal. For parcel shipping, it should be used as an inner component inside a mailer or master shipping box.

Why does this tray use so much material?

To achieve double walls on all four sides, the flat blank must extend outward in every direction. This provides high strength and clean edges, but it makes the flat footprint much larger than a single-wall tray.

Can I add hand holes to this tray?

Yes, hand holes can usually be added to the outer walls, provided they avoid the double crease areas at the top edge and the locking tabs at the base.

Why does board thickness matter so much for this tray?

The double-folded walls require the board to roll over itself. If the board is too thick, the outer layer can crack, and the locking tabs may not seat properly.