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FEFCO 0472

Heavy-Duty Double-Floor Tray

This one-piece open tray is engineered for bottom shock absorption. Instead of a standard single-layer base, the side walls feature wide extensions that fold inward to create a double-thick floor, which is then locked in place by roll-over end walls.

The result is a highly protective, clean-lined tray that excels at carrying heavy industrial parts or dense agricultural goods. Because the double floor requires more corrugated board and manual folding time than a standard tray, it makes the most sense when bottom strength and presentation outweigh the need for a minimal flat footprint and rapid packing speed.

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At a glance

  • Double-layered floor provides drop protection for heavy payloads
  • 180-degree roll-over end walls lock the structure without tape or glue
  • Open-top design requires a master carton or pallet wrap for transit

Common uses

  • Heavy industrial parts
  • Dense agricultural produce
  • Retail display for heavy items
  • Internal factory kitting totes

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Heavy Payloads and Clean Presentation

Heavy industrial components

The double-layered floor prevents dense metal parts or heavy hardware from punching through the bottom during lifting or transit.

Premium retail display

Because the interior flaps cover the base panel, they hide the locking slots. This creates a smooth, continuous interior floor that looks clean on a retail shelf and provides an excellent surface for inside-the-box printing.

Dense agricultural produce

The reinforced base and triple-thick end walls provide the rigidity needed to stack heavy produce on pallets, while the open top allows for ventilation and quick access.

Archival document storage

The reinforced bottom locks handle the concentrated weight of stacked paper files, making it a durable choice for long-term storage when paired with a separate lid.

Industrial Kitting, Agriculture, and Retail Display

Internal factory kitting

For moving heavy work-in-progress parts between stations, the tool-free assembly and integrated thumb cuts make this tray a durable, reusable tote.

Palletized distribution

When stacked on a pallet and stretch-wrapped, the reinforced end walls carry vertical weight effectively, while the double floor absorbs the shock of forklift handling.

E-commerce fulfillment

While it cannot ship on its own, this tray acts as a protective inner cradle for heavy items that are subsequently packed into a larger master carton for courier delivery.

When to Consider a Different Box or Tray

High-volume automated packing

This tray relies on two-handed manual assembly to seat the friction locks. If you are packing thousands of units a day on an automated line, a machine-erected glued tray is a faster choice.

Individual parcel shipping

Because this is an open-top tray, it cannot be shipped through a courier network on its own. If you need a standalone shipper, look at a closed mailer with a similar reinforced base.

Board Thickness, Assembly, and Print Choices

Board thickness and lock binding

This design is extremely sensitive to board thickness. The end walls must roll 180 degrees over two layers of corrugated board. Specifying a heavy double-wall board may cause the hinges to crack and the locking tabs to fail unless the fold clearances are perfectly tuned.

Material footprint

The flaps that form the double floor almost double the width of the flat cardboard blank compared to a standard tray. This wide footprint reduces how many trays can be cut from a single sheet.

Packing bench space

Because the flat blank is exceptionally wide before assembly, operators need a larger packing station to fold the side walls and seat the interior floor panels.

Interior print utilization

The double floor creates an uninterrupted interior canvas. If you plan to print inside the tray, this flat surface avoids the visual disruption of the locking slots found in standard trays.

Practical Template Adjustments

Thumb cut sizing

The ergonomic thumb cuts on the end walls can be resized or removed entirely if you do not need manual lifting features, which slightly increases the end-wall strength.

Lock hole friction

The width and depth of the tuck tongues can be adjusted to create a tighter or looser friction fit, depending on the board grade and whether the tray needs to be flattened and reused.

Display window cutouts

For retail applications, the front or side panels can be modified with die-cut windows to increase product visibility without compromising the double-floor locking mechanism.

Board and packing details

Die-cutting and stripping waste

The lock holes and thumb cuts require flatbed or rotary die-cutting. The small pieces of waste board from these holes must be actively stripped during production to prevent machine jams.

Additional notes

Manual locking pressure

Operators must apply firm thumb pressure to seat the locking tongues through the double-thick floor. This creates a highly secure friction fit, but it requires more manual effort than a simple glued tray.

Related Packaging

0422: Standard Single-Floor Tray

A better choice if you want a similar tool-free tray but do not need the extreme bottom protection, reducing the overall board footprint.

0470: Double-Bottom Mailer

Consider this alternative if you need the same reinforced floor but require a hinged lid for standalone parcel shipping.

0471: Hinged-Lid Mailer

Look at this option if you need a closed box for e-commerce or fulfillment, rather than an open tray.

FAQs

Shipping and Route

Can I ship this tray through a parcel courier?

Not on its own. Because it has an open top, the contents will fall out during mixed-carrier transit. It relies on an outer master carton or secure pallet wrap for transit.

Board and Fit

Is this tray a good candidate for heavy double-wall board?

It requires careful prototyping. The end walls must fold 180 degrees over the double-thick floor. If the board is too thick, the hinges may bind or crack, and the locking tabs may not reach their slots.

Production

Why does this tray require a larger flat footprint than a standard open tray?

To create the double floor, the side walls of the flat cardboard blank are extended inward. This large footprint means fewer trays fit on a single sheet of corrugated board during manufacturing.

Assembly

Can this tray be erected by automated tray erectors?

No. The sequence of folding the interior floor flaps flat and then rolling the end walls over them relies on manual, two-handed assembly on a packing bench.

Print and Presentation

Does the double floor affect inside printing?

Yes, in a positive way. The interior flaps cover the base panel and hide the locking slots, creating a smooth, uninterrupted surface that is excellent for inside-the-box branding or clean retail display.

Comparison

When should I drop down to a standard 0422 tray?

If your product is relatively light, or if the tray will always be fully supported by a pallet or shelf, the extra bottom strength of the 0472 may be unnecessary. Switching to a standard tray will noticeably reduce your board usage.

Reusability

Can this tray be flattened and reused?

Yes. Because it uses mechanical friction locks instead of glue, operators can carefully pop the tuck tongues out of the base slots to flatten the tray for return transit or storage.

Dimensions

Does the double floor affect the internal dimensions?

Yes. The interior bottom flaps add an extra layer of corrugated board to the floor, which slightly reduces the usable internal depth. This must be accounted for when sizing the tray for exact product fits.

A heavy-duty tray that prioritizes bottom strength and clean presentation for dense, demanding payloads.

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