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FEFCO 0911

Corrugated Lid and Base Tray

  • 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

  • Caps tubular sleeves or half-slotted containers for heavy-duty transport
  • Allows ergonomic drop-over packing for heavy or bulky equipment
  • Requires manual corner fastening and external strapping to secure the load

About this product

A flat-shipping corrugated sheet that folds into a shallow, open-faced tray. It is designed to act as a heavy-duty top cap or bottom base for tubular shipping sleeves, allowing packers to build a box around heavy or awkwardly shaped products.

Because it relies on simple corner slots, it requires operators to manually staple, tape, or glue the corners to hold its shape. The main tradeoff is packing labor versus loading ergonomics: it takes time to assemble the tray, but it saves workers from having to lift heavy equipment into a deep, pre-glued box.

Common uses

  • Base trays for heavy motors or pumps
  • Top lids for pallet-sized bulk bins
  • Open staging trays for industrial kitting
  • End caps for long, flat-pack furniture sleeves

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.

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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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Heavy equipment and industrial packing

Heavy equipment and appliance packing

Instead of lifting a heavy motor or appliance into a tall box, workers place the item on the base tray, drop a corrugated sleeve over it, and cap it with a second tray. This modular approach prevents lifting injuries and simplifies the packing process for dense items.

Pallet-sized bulk bins

Often used as the top cover for massive double-wall or triple-wall automotive sleeves. The simple tray design keeps the top of the bulk bin accessible without requiring complex, heavy flaps that are difficult to fold.

Industrial kitting and staging

The shallow profile works well as an open bin for staging heavy metal parts on an assembly line before the final outer sleeve is added for shipment.

Tall or awkwardly shaped product enclosures

When shipping items like standing lamps or industrial cylinders, packers can use a long sleeve capped at both ends with these trays, avoiding the need for a custom-height slotted box.

Sectors using modular tray-and-sleeve systems

Automotive and heavy manufacturing

These sectors handle dense components that require heavy board grades. The simple slotted design of this tray accommodates thick corrugated board that would otherwise bind or tear in complex self-locking folds.

Large-format distribution

Distributors shipping items that exceed standard box dimensions use these caps to seal custom-cut corrugated sleeves, creating a secure enclosure for long or bulky products.

Furniture and cabinetry shipping

Manufacturers of flat-pack goods often use long, narrow sleeves to protect panels. Capping the ends with these trays creates a tight, secure fit that prevents the heavy panels from sliding out during transit.

When to consider a different tray or box

When packing labor is the bottleneck

If operators cannot spend time stapling four corners per tray, compare this with a self-locking tray. Self-locking designs fold together without fasteners, though they require more board and a different manufacturing route.

When the product is light enough to lift

If the item can be easily dropped into a box by one person, a standard slotted container is usually faster to pack and seal than a three-piece tray-and-sleeve system.

Close variants and lookalike dielines

The closest library neighbors include 0912, 0452, 0459a. 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.

Fastening, fit, and board decisions

Corner fastening method

Decide whether your packing line will use industrial staples, heavy-duty tape, or glue. The tray arrives flat and unjoined, so the packing station must be equipped to lock the corners before the tray can be used.

Flange depth

The height of the side walls determines how much overlap exists for stapling to the main sleeve. Deeper walls provide a stronger grip and better load containment, but they increase the overall footprint of the flat blank.

Board grade and strapping tension

Because the final assembly is usually banded with plastic or steel strapping, the board must be thick enough to resist flaring outward under tension. Heavy single-wall or double-wall board is common for these applications.

Assembly timing

Determine if your team will pre-assemble stacks of these trays before the shift begins, or if operators will fold and staple them on demand as each product moves down the line.

Practical template adjustments

Slot width calibration

The corner slots must be cut to match the exact thickness of the chosen board. If the board grade changes later, the slot width must be updated so the corners fold cleanly without binding or tearing.

Flap overlap direction

The template can be adjusted to fold the length flaps inside the width flaps, or vice versa. This choice depends on where the staples need to sit to avoid interfering with the external strapping path.

Corner relief cuts

For extremely thick double-wall or triple-wall board, the corners can be modified with deeper relief cuts to ensure the folded flanges do not bind against the inner sleeve.

Board and packing details

Mating clearance and fit testing

The internal dimensions of the lid must be slightly larger than the outer dimensions of the sleeve it caps. A physical fit test is highly recommended before a full production run to ensure the lid slides on easily without tearing.

Blank sprawl and corner waste

The cross-shaped flat blank leaves empty space in the four corners during manufacturing. Very deep trays generate more corner waste, which means the package requires a larger overall footprint of corrugated board.

Alternative caps and pads

Flat pads versus folded trays

If you only need to separate layers inside a master carton rather than cap the outside of a sleeve, a simple flat pad avoids the folding labor and corner waste entirely.

Additional notes

Strapping and corner protection

When banding the final tray-and-sleeve assembly, the strapping tension transfers directly to the tray's side walls. Edge protectors are sometimes added under the straps to prevent the corrugated board from crushing.

Related packaging components

0422: Self-Locking Tray

A tray that folds and locks without staples, useful when packing speed matters more than board efficiency.

0912: Interior Form

Nearby FEFCO style to review if the buyer wants a similar job but the closure, flap overlap, wall build, or part count changes the package choice.

0452: Side Slotted Tray

Nearby FEFCO style to review if the buyer wants a similar job but the closure, flap overlap, wall build, or part count changes the package choice.

FAQs

Assembly and closure

Does this tray lock together on its own?

No. It arrives as a flat, scored sheet. Your packing team must fold the sides up and secure the four corners using staples, tape, or glue.

Route and shipping

Can this be used as a standalone shipping box?

It is rarely used alone for shipping. It is designed to cap a separate corrugated sleeve. The combined pieces usually require heavy strapping to keep the load secure during transit.

Product fit and packing

Why use a tray and sleeve instead of a normal box?

Ergonomics. Dropping a heavy appliance into a tall box is difficult and dangerous. Placing the appliance on a base tray and sliding a sleeve down over it is much safer for the packing team.

Board and finish

What board thickness makes sense?

Because these trays often cap heavy industrial loads and face tight strapping tension, heavy single-wall or double-wall board is typical. Fine flutes may tear when stapled.

Production and packing

Will this run on automated packing lines?

Standard box erectors cannot handle this flat cross-shaped blank. It requires manual assembly or specialized tray-forming equipment.

Samples and prototypes

How do I ensure the lid fits the sleeve?

The lid's internal dimensions must account for the outer thickness of the sleeve. We recommend testing a physical prototype to verify the slip-fit before ordering a full run.

Assembly and closure

Should we use staples, tape, or glue?

Industrial staples are the most common choice for heavy board grades because they hold securely under tension. Tape or glue can work for lighter applications, provided your packing station is set up for it.

Route and shipping

Does the tray need edge protectors?

Often yes. When banding the final tray-and-sleeve assembly, the strapping tension transfers directly to the tray's side walls. Edge protectors prevent the corrugated board from crushing under the straps.