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EVC41154

Pop-Up Tray with Split Lid

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

Opens in one motion for fast manual assembly
Two-piece lid creates a center-opening presentation
Relies on an external seal or tape for parcel shipping

About this product

This corrugated tray is designed for fast manual packing and a premium unboxing experience. The corners are pre-glued before delivery, allowing the packer to open the tray in one motion. The integrated lid is split into two panels that meet in the center, creating a theatrical 'double-door' presentation when opened.

While the pre-glued corner design saves labor at the pack bench, the split lid changes how the package handles in transit. It relies on an external seal or tape to stay closed during parcel shipment, and the lack of a continuous top panel means it is better suited for lightweight stacking or self-supporting products.

Common uses

Subscription boxes and kitting programs.
Retail shelf presentations.
Lightweight e-commerce shipments (when taped).

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Kitting, retail presentation, and lightweight e-commerce

Subscription boxes and kitting

The fast manual assembly makes this tray efficient for pack benches handling multi-item kits. The center-opening lid provides a high-end reveal for the end user.

Retail shelf presentation

When used unsealed or closed with a clear wafer seal, the split lid can be easily opened by retail staff or customers to display the contents.

Lightweight e-commerce

When secured with a strong label or tape across the center seam, the tray can serve as a shipping mailer for clothing, soft goods, or lightweight items that do not need heavy top-load protection.

Internal transfer and sorting

The fast assembly and solid base make this tray useful for moving parts or work-in-progress items between stations before the lid is closed.

High-volume pack benches and premium unboxing programs

High-volume manual packing

Because the factory handles the corner gluing, the packer only needs to push the corners inward to erect the tray. This reduces assembly time compared to folding a standard roll-end mailer.

Premium unboxing programs

The 'double-door' opening style mimics high-end presentation packaging, making it a practical option for influencer kits, welcome boxes, or limited-edition releases.

Fulfillment centers managing storage space

While the trays ship flat, the pre-glued corners create a slight thickness buildup in the stack. Facilities should plan for slightly fewer trays per pallet compared to unglued mailers.

When to compare single-lid mailers or heavy-duty shippers

When heavy pallet stacking is expected

The split lid does not provide the vertical crush resistance of a solid top panel. If the package will be stacked heavily on pallets without a master shipper, a standard slotted carton or a mailer with a full-overlap lid is worth comparing.

When running short digital trials

The pre-glued webbed corners rely on a specialized multi-point folder-gluer. For very short runs or prototypes, a manual-fold tray without glued corners will be easier and faster to source.

Closure methods, board thickness, and repeat volume

Closure method and transit route

The center tucks rely on friction. For parcel shipping, plan for a seal, such as a branded label, clear wafer seal, or packing tape across the center seam.

Board and flute selection

Thinner materials like E-flute or F-flute are recommended. Thicker double-wall boards will cause the pre-glued corners to bind and resist folding flat, making delivery and storage inefficient.

Repeat volume and packing speed

Because this tray relies on specific factory gluing equipment, it is generally geared toward repeat production programs rather than one-off short runs.

Insert and partition compatibility

The solid base supports die-cut inserts or dividers, but the split lid means any internal components should not interfere with the center tuck flaps when closed.

Lid support flanges, center tuck depth, and corner offset

Lid support flanges

The long walls feature top flanges that fold inward to keep the lid from falling into the tray. The width of these flanges can be adjusted based on the product clearance needed inside.

Center tuck depth

The depth of the center tuck flaps can be extended to increase friction and hold the lid halves more securely, though an external seal is still used for shipping.

Webbed corner offset

The diagonal fold geometry at the corners can be adjusted to accommodate different board thicknesses, ensuring the tray folds flat without tearing.

Packing details

Flat delivery and storage profile

Because the corners are folded and glued, there is a localized thickness buildup in the flat stack. This means fewer trays will fit on a pallet compared to completely unglued mailers.

Additional notes

Center seam artwork alignment

If your artwork spans across the top of the package, the graphics will be split down the middle. Slight folding variances can cause minor misalignments at the center seam.

Retail display presentation

The split lid can be folded all the way back or removed entirely along a perforation if the tray is intended for open-shelf retail display.

FAQs

Does this tray need tape for shipping?

The center-split lid relies on friction tucks. For parcel shipping, apply tape or a strong label across the center seam to prevent it from opening in transit.

Can this tray be erected by automated machinery?

This style is designed specifically for manual assembly at a pack bench. The pre-glued corners allow a human operator to open it in one motion.

Why is this style better for repeat programs?

The webbed corners are glued by the converter using a multi-point folder-gluer. The preparation time for this equipment usually makes it impractical for very short runs or prototypes.

Can this tray hold heavy items?

The solid base can support moderate weight, but the split lid cannot support heavy top loads. It is often used for lightweight items or products that are self-supporting.

What board thickness fits this tray?

Thin flutes, such as E-flute, fit well. Thicker boards create too much bulk at the glued corners, which prevents the trays from stacking efficiently when delivered flat.

How does the lid stay supported without falling in?

The long walls have top flanges that fold inward. The two lid panels rest on these flanges when closed.

Can I use custom inserts with this tray?

The solid base easily supports die-cut inserts, molded pulp, or corrugated partitions to separate multiple items.

How is this tray delivered?

It arrives folded flat. However, the pre-glued corners create a slight thickness buildup, meaning fewer trays fit on a pallet compared to standard unglued mailers.