Retail and Point-of-Purchase Display Jobs
Heavy-item counter displays
The double-layered floor makes this tray well-equipped for holding dense products like glass bottles, canned goods, or cosmetics. The reinforced base transfers weight to the side walls, keeping the tray flat and stable on retail counters.
Shelf-ready packaging (SRP)
Designed to move straight from a master shipping carton to the retail shelf. The high back provides a backstop for the products, while the sloped sides and low front lip make it easy for customers to reach the items.
Dense hardware and tool kits
For hardware items that might punch through or warp a single-wall base, the double bottom provides the necessary rigidity. The open top allows shoppers to inspect the tools or parts without opening a closed box.
Beverage and jar retail presentations
Glass jars and beverage cans exert concentrated weight on the floor of a display. The overlapping inner and outer bottom panels prevent the base from bowing when the tray is lifted or shifted on the store shelf.
Co-Packing and Shelf-Ready Workflows
Co-packing and manual assembly lines
Because the tray erects manually and locks via a roll-over front wall, co-packers can set it up quickly at the packing bench. It requires no specialized gluing equipment or tape, keeping the assembly area clean and straightforward.
Retailers requiring shelf-ready displays
Store staff prefer displays that do not require cutting or complex unpacking. This tray arrives loaded inside a master shipper, ready to be pulled out and placed directly on the shelf.
Brand owners needing two-sided print visibility
The high back wall and low front lip provide distinct branding zones. Brand owners can use the inside back wall for primary messaging and the outside front lip for pricing or secondary graphics.
Single-Bottom Trays and Master Shippers
Lighter products and material efficiency
If the items being displayed are lightweight, a standard roll-end tray with a single bottom will use less corrugated board and cost less to produce. The double bottom is specifically for preventing sag under heavy loads.
Transit and parcel shipping
This is an open-top display, not a shipping container. Products packed in this tray require an outer master carton to travel safely through distribution networks.
Board Thickness, Print Surfaces, and Fit
Two-sided print requirements
Retail displays often need graphics on both the inside of the high back wall and the outside of the front lip. Discuss whether your artwork requires two-sided printing or specific mottled liners to achieve the right presentation.
Flute profile and locking clearance
A standard B-flute offers a good balance of rigidity and crisp folding. If a thicker board like C-flute is chosen for extra strength, the front locking tabs and slots must be carefully adjusted to ensure they still engage smoothly.
Master shipper sizing
Because the display has an open top and a high back wall, the outer shipping carton must be sized to protect the back panel from crushing or scuffing during transit.
Assembly labor planning
The folding sequence for the inner and outer bottom flaps requires manual packing. Plan for hand assembly at the fulfillment center rather than relying on automated tray-forming machinery.
Front Lip Height, Side Slopes, and Clearances
Front lip height
The low front panel can be raised or lowered to expose more of the product or provide more retention, as long as it remains shorter than the overall tray height.
Side wall profile
The slope and curve of the side walls can be modified to match the shape of the product or to create a specific visual frame for the display.
Locking tab dimensions
The size of the locking tongue on the inner front wall can be adjusted based on the board thickness to ensure a secure hold without tearing the corrugated material.
Packing details
Blank size and flatbed die-cutting
The cross-shaped flat blank required to form the double bottom takes up considerable space on a corrugated sheet. This tray requires flatbed die-cutting to produce the rounded corners, sloped sides, and locking slots.
Additional notes
Print panel and scuff risk
Because the back wall extends upward, its printed surface may rub against the inside of the master shipper during transit. A protective varnish or careful master-carton sizing can help prevent scuffing before the display reaches the retail shelf.
Related Display and Tray Options
FAQs
Does this tray require glue to stay together?
No. The tray uses a mechanical roll-over front wall that wraps over the side flaps and locks into slots in the bottom panel, securing the entire assembly without adhesive.
Can this tray be erected by automated machinery?
It is designed for manual assembly at a packing station. The folding sequence for the inner and outer bottom flaps usually requires hand packing rather than standard automated tray formers.
Why choose a double bottom over a standard tray?
A double bottom prevents the floor from sagging when the tray is lifted or placed on a shelf. It is often chosen for dense items like beverages, jars, or heavy cosmetics.
Can I ship this tray directly to customers?
Because it has an open top and sloped sides, it cannot contain products during rough transit. It must be packed inside a closed master shipper for distribution.
Where does branding usually go on this display?
The most visible areas are the tall inside back wall (which sits behind the products) and the outside of the low front lip. This often requires two-sided printing depending on the board choice.
Can this be cut on basic slotting equipment?
The sloped sides, rounded corners, and specific locking slots require flatbed die-cutting rather than simple straight cuts.
Will a thicker board make the tray stronger?
A thicker flute like C-flute increases base rigidity, but it also makes the front roll-over lock tighter. The locking tabs and slots must be adjusted to accommodate the extra thickness.
How is the display protected during transit?
The loaded display tray is placed inside a master shipping carton. The outer carton must be sized carefully to prevent the high back wall of the display from bending or scuffing against the top flaps.
