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FEFCO 0415

Fully Enclosed One-Piece Folder with Dust Flaps

  • 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

  • One-piece folder with closure flaps and dust flaps
  • All represented variants form enclosed boxes, not open trays
  • Corners require the specified production fastening method

About this product

This one-piece corrugated folder forms a fully enclosed box with opposed closure flaps and dust flaps at the corners.

The represented 0415, 0415_1, and 0415a forms all retain their enclosing flap sets; none is a separate open-tray form.

Common uses

  • Shelf-ready retail displays
  • Flat e-commerce and apparel shipping
  • Internal warehouse transit trays
  • Pizza-style flat cartons

Get a quote

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

Best Price Guarantee

Already have a packaging quote? Let us beat it.

Send us the quote you have. We will beat it for the same specifications, quantity, and delivery requirements.

Upload a competing quote

Free quote review. No obligation.

30+specialist partner plants

We supply through the plant best suited to your price, material, production, and delivery requirements.

Why we can beat a lower quote

30+ plants give us more ways to lower the price.

Each plant has different machinery, material costs, order minimums, and freight rates. Our buying volume helps us secure better pricing. We then quote through the plant that gives you the lowest total price for your requirements.

Send us your current quote. Watch us beat it.

Attach it to the quote form or email it to us. We'll review it free and send you our price.

Upload a competing quoteinfo@herculeindustrial.com
Best Price Guarantee terms

To qualify, send a written supplier quote dated within the past 30 days and addressed to your company. It must cover the same dimensions, construction, material, print, finish, quantity, tooling, freight, delivery date, and delivery location. The guarantee does not cover taxes, expired quotes, liquidation or clearance sales, or obvious pricing errors.

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Retail, fulfillment, and transit applications

Shelf-ready retail displays

The open-top base tray provides clean, continuous side walls without external seams. This creates an uninterrupted front panel for printed branding, making it a strong candidate for store displays.

Flat e-commerce and apparel shipping

Adding top flaps converts the tray into a secure, flat mailer. The glued or taped corners prevent the side walls from bulging open, which is common in slotted boxes when shipping dense, shallow items through courier networks.

Internal warehouse transit

The open tray configuration allows fast top-loading and quick access. It fits kitting, parts distribution, or moving work-in-progress components between assembly stations.

Pizza-style flat cartons

The shallow enclosed variant works well for food delivery or flat goods that require a wide, uninterrupted base panel and a top lid that opens fully for presentation.

Operations relying on this tray style

Fulfillment centers with tray erectors

Operations equipped with automated tray erectors benefit from the extreme assembly speed of this tray. They trade the higher material offcut waste of the cross-shaped blank for faster packing throughput.

Retail and consumer goods brands

Brands needing shelf-ready packaging rely on the crisp 90-degree corners and clean display edges to maintain presentation on the store shelf.

Apparel and flat-goods shippers

Operations shipping clothing, books, or framed items use the enclosed variant to keep shallow products secure without the void space of taller boxes.

When a different folder or tray is a better choice

Manual pack benches without gluing equipment

If operators must fold and hold boxes by hand, the 0422 self-locking tray is worth evaluating. It uses friction tabs instead of glue, speeding up manual assembly.

Heavy, long industrial extrusions

If the product is difficult to drop into a tray, the 0414 wrap-around folder allows packers to build the box around the item and features double-thick side walls for heavy metal or wood components.

Extremely wide, shallow panels

For large flat items like framed art or furniture panels, the 0412 cross-fold mailer wraps tightly around the edges and reduces corrugated board usage for oversized flat goods.

Close variants and lookalike dielines

The closest library neighbors include EVC30001, 0413, 0412. Use this as a variant check if a buyer brings an old code, sample, or dieline that looks close. The deciding details are usually the lock, slot, closure, wall build, part count, or fold sequence.

Closure, assembly, and board choices

Open tray versus full enclosure

Decide if the product needs the open access of the base tray for retail display, or the full top-flap enclosure of the mailer variant for parcel shipping.

Automated versus manual assembly

Confirm whether the trays will be formed on a hot-melt erector or taped by hand. This affects the fold clearances required and whether a self-locking alternative is a better financial choice.

Board thickness and corner clearance

Thick double-wall board can cause the folded corners to bind and jam automated machinery. The crease offsets must be adjusted if heavy flutes are required for your product weight.

Print orientation for retail

Because the end walls fold up and the dust flaps fold in, graphic layouts must account for the specific folding sequence to keep branding upright on the finished tray.

Practical template modifications

Top flap coverage

For the enclosed variant, the top flaps can be adjusted to leave a gap, meet in the middle, or fully overlap depending on the required tape seal and top-crush resistance.

Machine-specific fold clearances

The corner cutouts and crease offsets can be tuned to match the exact mandrel and plow tolerances of your specific tray erecting equipment.

Wall height adjustments

The side and end walls can be extended for deeper products, though taller walls increase the overall blank size and must remain within the limits of the erecting machinery.

Board and packing details

Blank sprawl and material yield

The cross-shaped flat blank creates four large rectangular offcuts. This lower material yield is the primary economic tradeoff for achieving clean corners and fast machine assembly.

Print orientation for retail

Because the end walls fold up and the dust flaps fold in, graphic layouts must account for the specific folding sequence to keep branding upright on the finished tray.

Enclosed and clearance variants

0415_1 Enclosed Mailer

Adds top flaps hinged to the end walls, converting the open tray into a fully sealable box for courier transit.

0415a Clearance Variant

Adjusts the internal crease offsets and slot depths to prevent corner binding on specific automated tray erectors.

Additional notes

Tooling requirements for corner slots

The specific cutouts separating the dust flaps from the end walls require flatbed or rotary die-cutting. This style cannot be produced on a simple slitter-scorer, meaning it involves specific die-cutting preparation.

Related folders and trays

EVC30001: One Piece Folder with Dust Flaps

EngView neighbor that can look close in CAD. Review it if a sample or dieline seems similar, then verify closure style, slots, wall build, and assembly before treating it as a substitute.

FAQs

Packing labor and assembly

Can this tray be assembled by hand?

Yes, but it is labor-intensive. An operator must fold the walls and hold all four corners square while applying tape or glue. If you do not have automated erecting equipment, a self-locking tray is usually faster for manual pack benches.

Closure and sealing

Does the enclosed version need tape to stay closed?

Yes. The top flaps do not have native friction locks or tuck tabs. The box relies on a strip of tape across the top seam to secure the lid and maintain tension during transit.

Board and material choices

Can we use double-wall corrugated board for heavier items?

It is possible, but thick board demands precise adjustments to the corner fold allowances. Without these corrections, the thick board will bind, causing the corners to bulge and potentially jamming automated erectors.

Shipping route

Is the open tray suitable for parcel shipping?

No. The open-top base tray exposes the product, and the corners can catch on courier sorting belts. It should only be used for parcel transit if placed inside a master shipper or if you switch to the enclosed mailer variant.

Production path and cost

Why does this style use more material than a standard slotted box?

The flat layout resembles a cross, which leaves four large empty rectangular spaces at the corners of the blank. This offcut waste is the tradeoff for achieving clean, continuous side walls and fast machine assembly.

First product context

What product and packing details help specify this tray?

Share the exact internal dimensions, the product weight, whether you need the open or enclosed version, and the specifications of your automated tray erector if you are using one.

Comparison and alternatives

What is the difference between the 0415 and the 0422 tray?

The 0415 is designed for machine erecting and relies on hot-melt glue or tape to hold its shape. The 0422 uses friction tabs to lock itself together, making it much faster for manual assembly without machinery.

Product fit and limits

Can the 0415_1 mailer be used for heavy bulk goods?

It is generally better suited for flat, stable items. Heavy, shifting bulk goods can put too much outward pressure on the glued corners, potentially causing them to split during rough transit.