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ECMA B30.02.00.00

Pre-Glued Double-Wall 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

  • Long walls are pre-glued flat during production
  • Short walls lock via friction-fit expansion tabs
  • Pairs with a separate lid for full enclosure

About this product

This premium double-wall tray delivers the clean, rolled edges of a high-end retail box while reducing hand-assembly time. By having the long walls pre-glued flat before delivery, packers only need to fold and lock the short ends to square the tray.

Often used as the base for two-piece shirt boxes, apparel packaging, and gift sets, it balances the structural rigidity of a double-wall design with an efficient fulfillment process.

Common uses

  • Apparel and shirt boxes
  • Cosmetics and skincare kits
  • Premium baked goods
  • Gift sets requiring custom inserts

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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Premium Retail and Apparel Presentation

Two-piece apparel and shirt boxes

The double-thick walls hide raw corrugated or paperboard edges, creating a smooth, framed presentation suited for folded garments. It serves as the rigid base, pairing with a separate lid to complete the classic setup box.

Cosmetics and gift sets

The reinforced walls provide excellent crush resistance and a premium unboxing feel. The flat inner floor easily accepts custom inserts, molded pulp, or die-cut partitions to hold multiple items securely.

Premium baked goods and confectionery

When produced with food-safe boards and coatings, the clean edges and rigid walls offer a high-end presentation for chocolates, pastries, or specialty foods.

High-end stationery and document sets

The precise right angles and double-wall rigidity protect corners of premium paper products, notebooks, or greeting cards, keeping them flat and pristine.

High-Volume Hand Packing and Kitting

Fulfillment centers managing seasonal volume

Because the long walls are already glued and folded flat, operators skip two manual folding steps per box. This increases packing throughput during peak seasons compared to fully unglued trays, without sacrificing the high-end look.

Retail brands upgrading unboxing presentation

Brands moving away from single-wall folding cartons often choose this tray to achieve a rigid-box aesthetic while keeping flat-shipping logistics and manageable assembly times.

Kitting operations using custom inserts

The flat, unobstructed floor and straight vertical walls make it easy to drop in foam, molded pulp, or paperboard inserts without interference from diagonal corner folds.

Evaluating Assembly Speed Versus Production Complexity

When to consider a fully unglued tray

If you are running a short prototype batch or prioritizing a simpler production route, an unglued double-wall tray (B10.02.00.00) can be cut on a simple flatbed. It looks identical when assembled but requires the packer to fold all four walls manually.

When to consider a four-corner glued tray

For the absolute fastest manual setup, a four-corner glued tray (B48.02.00.00) erects in one motion. However, it involves more complex manufacturing and may not offer the exact rolled-edge aesthetic on all four sides.

Board Caliper, Grain Direction, and Fit

Matching board thickness to the fold-over allowance

The short walls fold over the corner tabs and lock into the base. The crease offsets should be precisely calibrated to your chosen board caliper, otherwise the locking flaps will either bind or fit too loosely.

Grain direction for the pre-glued walls

The long walls undergo a tight 180-degree fold during production. Orienting the board grain parallel to these folds helps prevent the outer liner from cracking, ensuring a pristine edge on the finished tray.

Insert clearance and floor locks

The friction-fit expansion pieces sit slightly above the base panel. If using a rigid insert, the internal dimensions should account for these tabs to ensure the insert seats flat.

Lid style and friction fit

Because this tray forms the base of a two-piece set, the outer dimensions should be carefully matched to the corresponding lid. The double-wall thickness affects the overall footprint and how tightly the lid grips the base.

Adjusting the Friction Lock and Wall Proportions

Expansion piece depth

The friction-fit tabs that lock the short walls can be lengthened for a more secure hold against the floor, which is useful for heavier boards or deeper trays that might otherwise bow outward.

Wall height and proportion

The height of the double walls can be adjusted to match the product depth. Very shallow trays may have less locking tension, while very deep trays use more board material for the fold-over panels.

Locking tab variations

While this template uses a full expansion piece that seats against the floor, variants can use smaller friction nibs on the fold-over ends if a full floor lock interferes with a specific insert.

Board and packing details

Lid compatibility and clearance

Since this tray forms the base of a two-piece set, the outer dimensions should be carefully matched to the corresponding lid. The double-wall thickness should be accounted for when calculating the internal volume available for the product.

Additional notes

Insert clearance for small parts

If you are using a rigid insert, ensure it clears the expansion pieces that lock the short walls to the floor, as these tabs sit slightly above the base panel.

Alternative Double-Wall Trays

FAQs

Assembly and Packing

Does this tray need packing tape or adhesive during fulfillment?

No. The long walls are pre-glued before delivery. On the packing line, the operator simply folds up the short walls, which lock into place using friction-fit tabs.

Manufacturing and Route

Why choose a pre-glued tray over an unglued one?

Pre-gluing shifts labor from the fulfillment center to the production stage. It reduces the time it takes a packer to erect the tray, making it efficient for large retail rollouts.

Materials and Fit

Can this be made from heavy corrugated board?

It is typically made from folding carton board (FBB or SBS) or very fine micro-flute. Heavier corrugated grades often struggle with the tight 180-degree fold required for the pre-glued long walls.

Does the double wall reduce the internal space?

Yes. The fold-over panels take up internal volume. When sizing the tray for a specific product or insert, the board thickness should be factored in twice for each wall.

Shipping and Route

Can this tray be shipped as a standalone parcel?

No. This is an open tray designed for retail presentation. It pairs with a matching lid to enclose the product, and the completed two-piece box usually ships inside an outer corrugated shipper for courier networks.

Assembly and Packing

Can this tray be erected by automated machinery?

Yes, it is rated for both manual and automated setup. Specific tray-forming machinery can fold and lock the short walls, though it is also very fast to assemble by hand.

Shipping and Route

How does the pre-glued wall affect flat shipping dimensions?

Because the long walls are folded flat and glued, the knocked-down flat (KDF) footprint is slightly wider than a fully unglued blank, but it still stacks efficiently on pallets for delivery to the packing facility.

Materials and Fit

What type of lid pairs well with this base?

It is commonly paired with a telescopic lid (such as the B50 series) or a transparent slipcover. The lid dimensions are calculated based on the outer footprint of the assembled double-wall base.