Dieline

EVC41070

Corrugated Foot-Lock Tray

Available in a wide range of custom configurations & material selection.
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Product details

Top highlights

Glue-free manual assembly
Open top for display or shrink-wrapping
Ships flat for dense pallet storage

About this product

The corrugated foot-lock tray is a glue-free, open-top package that ships flat and locks together by hand. It uses diagonal corner creases and a central friction tab that snaps into the base, creating reinforced ends without requiring adhesive or tape.

Because it relies entirely on manual assembly, this tray trades automated packing speed for flat-storage efficiency and zero gluing costs. It is widely used for retail displays, produce handling, and as a rigid base for shrink-wrapped multi-packs.

Common uses

Retail shelf-ready displays
Produce and bakery transport
Rigid bases for shrink-wrapped multi-packs
In-plant work-in-progress (WIP) handling

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Retail display, produce, and multi-pack bases

Shelf-ready retail displays

The open top provides immediate product visibility, while the reinforced rolled ends offer enough rigidity to handle the transition from the stockroom to the shelf. The lack of a lid means retail staff do not have to tear or cut away flaps before displaying the goods.

Rigid bases for shrink-wrapped multi-packs

When grouping bottles, cans, or jars into a single retail unit, this tray provides a stable, flat floor. Once loaded and shrink-wrapped, the tension of the film works with the foot-lock ends to create a secure, stackable package.

In-plant work-in-progress (WIP) transport

For manufacturing environments moving parts between stations, these trays can be erected on demand, stacked when loaded, and broken down flat when empty, saving floor space compared to rigid plastic totes.

Produce and agricultural packing

The open design allows for airflow and moisture venting, which is useful for fresh produce. The glue-free construction also removes concerns about adhesive failure in humid or refrigerated environments.

Grocery, beverage, and industrial distribution

Grocery and bakery distribution

Produce and baked goods often require breathable, open-top packaging that can be assembled quickly in the back room. The mechanical lock holds up well in environments where moisture might weaken standard glued joints.

Beverage and canned goods packaging

Operations that bundle heavy cans or bottles rely on the double-thickness rolled ends to prevent the tray from bowing when lifted. The tray acts as a stabilizing floor for the final shrink-wrapped bundle.

Industrial parts handling

Facilities that need temporary, reusable bins for sorting components benefit from a tray that can be stored flat and folded together by operators directly at their workstations.

When to consider glued or lidded alternatives

High-volume automated packing lines

If the operation requires thousands of trays per hour, the manual folding required for a foot-lock tray will create a bottleneck. A four-corner glued tray that can be erected instantly by machine or pops open by hand is usually a better fit.

Parcel and courier shipping

This tray has no lid and no native way to seal the top. If the product is entering a mixed-carrier parcel network, it usually needs an outer master carton, or the choice should shift to a full roll-end tuck-top mailer.

Board thickness, print placement, and packing labor

Pack-bench labor versus gluing costs

This tray costs less to manufacture because it skips the folder-gluer line, but it shifts the assembly time to the packing team. The savings on the empty corrugated blank should be weighed against the hourly cost of manual folding.

Flute profile and lock binding

The foot-lock mechanism relies on folding corrugated board over itself. E-flute is a common choice because it folds cleanly. If thicker B-flute or C-flute is specified for heavier payloads, the score allowances should be widened so the locking tab does not bind or crack the board.

Print visibility on rolled ends

Because the end walls roll over the corner flaps and face inward, the exterior print surface will be visible on the inside of the tray's ends. This is a useful detail for retail displays where interior branding matters.

Outer shipping requirements

Since the tray leaves the top exposed, buyers should decide early whether the loaded trays will be stacked on pallets, shrink-wrapped, or placed inside larger shipping boxes for distribution.

Locking tab and corner adjustments

Locking tab angle and depth

The central foot that snaps into the base can be adjusted in height and taper. A deeper tab provides a more secure lock for heavy contents, while a shallower tab is easier for packers to snap into place quickly.

Score allowances for thicker board

The template allows adjustments to the layer step creases. This ensures that when the end panels roll over the corner flaps, the extra board thickness is accommodated without crushing the corners.

Base footprint and wall height proportions

The length, width, and height can be scaled to fit specific product arrangements, though very tall walls may make the roll-over folding motion more difficult for packers.

Packing details

Die-cutting and tooling requirements

Because of the specific diagonal creases and the precise angle of the locking tab, this tray requires a custom cutting die and is typically produced on flatbed die-cutting equipment.

Additional notes

Hand folding ergonomics

For high-volume manual packing, the repetitive motion of rolling the end panels and snapping the foot locks should be evaluated for packer fatigue.

FAQs

Does this tray require tape or glue to stay together?

The tray relies entirely on a mechanical foot-lock rather than adhesive. The end panels roll over the corner flaps, and a central tab snaps into the base using friction to hold the shape.

Can this tray be erected on automated equipment?

The diagonal creases and roll-over locking sequence are designed for manual pack-bench assembly. Standard linear folder-gluers are usually not equipped to erect this style without specialized tray-forming validation.

Is heavy double-wall corrugated a good fit for this tray?

Double-wall board is usually a poor match. The end walls fold over 180 degrees to trap the corner flaps, and thick board often cracks during this fold or prevents the foot-lock from engaging properly.

Is this tray suitable for shipping directly to customers?

Because it is an open-top tray, it lacks a native seal. To ship through a parcel network, it usually needs to be placed inside an outer carton or fully enclosed in a heavy shrink wrap.

Where does the outside print show up on the inside?

When the end walls roll over to lock the tray, the exterior surface of the corrugated board becomes the interior face of those two ends. This allows exterior branding to carry to the inside without paying for two-sided printing.

What should be checked when testing a physical sample?

Test the assembly speed with the packing team, and verify that the foot-lock tab snaps cleanly into the base without tearing. If the board thickness changes, ensure the rolled ends do not crush the corner flaps.

How does the foot-lock mechanism stay closed?

The central tab on the rolled end panel creates friction against the base of the tray. The tension of the folded corrugated board keeps the tab pressed into place.

Does the tray ship flat or pre-assembled?

The tray is delivered flat to maximize pallet density. It is then folded and locked together by the packing team right before loading.