Products packed in integrated hole trays
Dairy and chilled food distribution
Holds yogurt cups, dessert pots, and conical dairy containers upright during transit, keeping them separated to prevent rim damage.
Horticulture and nursery transport
Secures small potted plants. The open top allows foliage to breathe while the locked false floor prevents the pots from tipping during pallet movement.
Beverage and cosmetic sampling
Acts as a presentation tray for conical bottles or tubes, keeping the labels facing forward for retail or kit display.
Fragile jar and candle packing
Suspends heavy glass containers so they do not collide during transit, relying on the false floor to absorb lateral movement.
Packing environments and logistics loops
High-volume manual pack benches
When packing speed is the primary bottleneck, removing the step of folding a separate internal divider saves significant labor across thousands of units.
Chilled logistics loops
Often specified with wet-strength liners to survive condensation in refrigerated dairy supply chains without the locking tabs softening and failing.
Co-packing and fulfillment centers
Simplifies inventory management by reducing a two-piece tray-and-insert combination into a single SKU that arrives flat and pops open in one motion.
When to compare two-piece or partitioned alternatives
Short runs and prototype testing
Compare a standard auto-bottom base paired with a separate die-cut insert. Two simpler pieces require less complex flatbed cutting and generate less stripping waste, though they require more time to assemble on the floor.
Fully enclosed shipping
Compare a standard slotted box with a corrugated partition if the package must ship as a standalone parcel through courier networks, as the 0751 has an open top.
Board, fit, and route decisions
Cup fit and hole sizing
The die-cut holes must match the exact taper of your product. If the holes are too wide, the cups slip through to the base. Physical product samples are necessary to set the correct radius.
Board thickness and locking tabs
The false floor relies on friction-fit tabs inserting into side-wall slots. Heavy double-wall board can make these tabs too stiff, causing them to crush rather than seat properly during manual assembly.
Wet-strength liner requirements
If the tray will move through refrigerated supply chains, standard kraft board can absorb moisture and soften. Wet-strength liners ensure the false floor remains rigid under condensation.
Hole spacing and grid density
Placing the cutouts too close together weakens the corrugated board between the cups, increasing the risk of tearing if the payload shifts during transit.
Grid and layout adjustments
Grid layout and hole count
The template adjusts to different configurations, such as a 2x3 or 4x3 grid, depending on the product diameter and the maximum flat blank size the folder-gluer can handle.
Mixed hole diameters
While a uniform grid is standard, the cutouts can be sized differently to hold a mixed assortment of products, such as a large jar and two small bottles in a single kit.
Ventilation and hand-hole cutouts
The side walls can be modified with circular or pill-shaped cutouts to improve airflow for agricultural products or to provide grip points for manual lifting.
Board and packing details
Flatbed die-cutting and stripping waste
The circular cutouts generate substantial scrap board. This design makes the most sense when the labor savings at the pack bench outweigh the higher material usage.
Vertical stacking limits
Because the top is open and the internal panel sits below the rim, vertical pallet weight transfers either through the cups themselves or requires a separate master shipper.
Base and lock variations
Alternate tab profiles
The locking tabs on the false floor can be cut with different hook or notch profiles to match specific factory stripping capabilities or to increase the friction fit against the side walls.
Additional notes
Chilled environments and condensation
If the tray will move through refrigerated supply chains, standard kraft board can absorb moisture and soften. Discuss wet-strength liners early to ensure the false floor remains rigid.
Physical cup samples for tolerance testing
Do not rely on digital measurements alone. Send physical samples of the cups or pots to the manufacturer to verify the exact drop depth and rim catch.
Related trays and inserts
FAQs
Shipping and route
Can this tray ship as a standalone parcel?
No. The open top provides no primary lid containment. It acts as a transport crate for palletized loops or requires an outer master carton for courier delivery.
Assembly and closure
Do I need to tape the bottom?
No. The crash-lock base is pre-glued at the factory and interlocks mechanically when the tray is opened.
Comparison
Why choose this over a separate insert?
It comes down to labor versus production complexity. A single-piece design requires more complex flatbed cutting but allows a packer to erect the tray and the cup holder in one continuous motion.
Materials
What board flute works best?
Fine to medium flutes like E or B are usually preferred. They provide crisp folds for the locking tabs and clean edges for the circular cutouts without causing the base to bind.
Product fit
Can the hole sizes vary in the same tray?
Yes. While a uniform grid is standard, the cutouts can be sized differently to hold a mixed assortment of products in a single kit.
Assembly and closure
Does this work on automated case erectors?
It depends entirely on the specific machinery. The complex fold-down and lock motion of the top panel is primarily designed as a highly efficient manual pack-bench solution.
Print surface
Can the false floor be printed?
Yes. Because the false floor is an extension of the main blank, it can be printed in the same pass as the exterior walls, making it useful for branded retail displays.
Product fit
Is it difficult to remove the cups once packed?
The cups are held by gravity and friction against the tapered holes. As long as the hole radius is sized correctly, the cups lift out easily without binding against the board.
