Product and Sorting Uses for the Open-Front Tray
Document and Literature Sorting
The classic paper tray geometry allows flat items, brochures, or documents to be stacked and retrieved easily. The open front prevents users from having to reach over a lip to grab the bottom sheet.
Retail Shelf Display
For flat-packed goods or small items, the tray keeps products organized on the shelf while keeping the primary packaging fully visible. The rolled top edges provide a clean, professional appearance.
Internal Kitting and Parts Bins
Used on assembly lines or in fulfillment centers, the tapered sides guide hands inward, allowing workers to quickly pick parts without obstruction.
Mailroom and Sorting Stations
The open-front design allows for rapid sorting of incoming envelopes or small packets, making it a lightweight alternative to permanent plastic or metal sorting bins.
Retail, Office, and Warehouse Environments
Office Supply and Organization
When produced in white or mottled liner, this tray serves as an economical, lightweight alternative to plastic or metal desk organizers.
Retail Merchandising
The double-wall sides provide enough stiffness to handle repeated customer interaction, while the open front ensures the product remains the focus.
Fulfillment and Assembly Lines
For operations that involve rapid component picking, the lack of a front wall reduces hand fatigue and speeds up the kitting process.
When to Consider a Four-Wall Tray
Containment for loose items
If the products are prone to rolling or sliding forward, the open front will not hold them. A four-wall roll-end tray may be worth comparing to ensure complete containment.
Stacking loaded trays
This tray has zero vertical compression strength at the front. If you plan to stack loaded bins on top of one another, a stackable bin design or a shelving unit is usually necessary to bear the weight.
Board Thickness and Print Planning
Flute and fold clearance
The side and back walls fold over 180 degrees to lock into the base. Thinner materials, like E-flute, yield crisp folds and clean edges. Thicker boards call for careful adjustment to the fold allowances to prevent the inner panels from bowing.
Single-sided print advantage
Because the inner panels fold over from the outside, the interior of the side and back walls will display the same liner as the exterior. This allows for full branding on the visible surfaces using only single-sided printing.
Master carton planning
Since this tray is not shipped on its own, you should plan the dimensions of your outer master carton to accommodate the exact footprint of the assembled trays.
Base slot tolerances
The tuck tongues lock into slots in the base panel. The width of these slots should be matched to the chosen board thickness so the tabs seat firmly without tearing the corrugated material.
Adjusting the Taper and Dimensions
Side wall taper angle
The angle of the side walls can be adjusted. A steeper taper exposes more of the product from the side, while a shallower taper provides more lateral containment.
Back wall height
The height of the back wall can be extended to provide more support for taller documents or to create a larger print space for retail branding.
Tuck tongue width
The width of the locking tabs can be modified. Wider tabs offer a stronger mechanical lock for heavier board grades, while narrower tabs are easier to assemble by hand.
Packing details
Flat delivery and storage
The trays are delivered flat and stacked. The lack of a front wall makes the blank slightly asymmetrical, but it remains efficient for storage before use.
Additional notes
Board thickness and locking tabs
If a thicker board is specified for durability, the die-cut slots in the base should be widened to accommodate the thicker locking tabs, ensuring the tray does not tear during assembly.
FAQs
Do I need glue or tape to assemble this tray?
No. The tray uses a mechanical lock. The inner panels of the sides and back fold over and insert tuck tongues into slots in the base, holding the shape securely.
Can I ship products directly in this tray?
No. The open front provides no protection or containment for transit. It should be placed inside a master shipping carton if moving through a courier network.
Can I stack these trays on top of each other?
Not when loaded. The open front means there is no vertical support at the front edge. Stacking will crush the tray and damage the contents.
How does the double-wall construction affect printing?
It is efficient for branding. Since the side and back walls fold inward from the outer sheet, a single-sided print run will cover both the outside of the tray and the inner walls.
What board thickness is a good fit for this design?
Thinner profiles like E-flute or F-flute are generally preferred. They allow the 180-degree folds to lay flat and lock cleanly without consuming too much internal space.
How is the tray delivered?
It is die-cut and delivered flat. It is assembled by hand at the point of use, which saves space in your facility before packing.
Are custom inserts compatible with this tray?
Yes, flat pads or custom dividers can be placed inside to separate parts, though the open front means inserts should be self-supporting.
What happens if I use a heavy B-flute board?
Thicker boards consume more internal volume when folded 180 degrees. The die-cut slots and fold allowances should be recalculated to prevent the inner panels from bowing or tearing.
