Interactive 3D

1 / 3

EVF41044

Double-Wall Roll-End 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.

Get pricing

Free white-glove consultations. Blazing-fast response time. Fast quotes.

Product details

Top highlights

Unglued friction-lock assembly
Double-wall sides for rigid presentation
Clean top edges with no exposed raw board

About this product

This unglued, double-wall tray is designed for retail presentation and kitting. By folding the side panels 180 degrees over interior corner flaps, it creates a rigid, clean-edged container with no exposed raw board at the top rim.

Because it relies on friction locks and precise folding rather than adhesive, it ships flat and is erected at the packing station. The double-wall construction provides structural support for paperboard, making it a useful choice for high-end displays, cosmetics, or inner trays that slide into a separate sleeve.

Common uses

Retail shelf trays
Premium kitting
Inner trays for sleeves

Get a quote

Share what you know. We'll take it from there. Or email us at info@herculeindustrial.com

Describe your project *

Approximate quantity *

Size if known

Files or competing quote (optional)Drag files here or choose filesAdd drawings, photos, dielines, quotes, specs, or other useful files.Max 5 files, 25 MB total.

Name *

Email *

Phone

Optional

More details

You can skip this whole part, or open a section and answer only what you know.

Size and quantity

Detailed dimensions

Units US customary (inches)Metric

What do your dimensions describe?

Length

Width

Depth

Size notes

Quantity notes

Materials and print

Paperboard preference

Add details for paperboard preference

Paperboard details

Print and artwork

Add details for print and artwork

Print, finish, or artwork details

Shipping or storage context

Custom changes or unusual needs

What will this tray hold?

How will this tray be presented?

How will these trays be packed?

Current box or specs

Do you have a current box, spec, or target sample?

Add details for do you have a current box, spec, or target sample?

Current box, known specs, or current problem

Destination ZIP or region

Company

Any deadline or timing constraint?

Retail Presentation and Kitting Roles

Retail Shelf Display

The double-folded walls hide raw edges, providing a clean, premium look for cosmetics, electronics, or specialty foods.

Premium Kitting

Acts as a rigid base for organizing multiple components, often paired with custom inserts or partitions.

Inner Drawer or Sleeve Tray

The smooth, double-wall exterior slides easily into a matching paperboard sleeve for a complete unboxing experience.

Bakery and Confectionery

The clean interior presentation without glue seams makes it a frequent choice for wrapped baked goods or specialty chocolates.

Packing Environments and Channels

Hand-Packing Operations

Fits operations where trays are erected on demand without automated gluing equipment.

Premium Retail Channels

Appeals to brands needing a polished interior presentation, as the 180-degree folds bring the printed front side of the board into the inside of the tray walls.

Multi-Component Kitting

Useful for operations assembling gift sets or sample packs where the tray serves as a rigid base for custom inserts.

When to Consider Glued or Corrugated Alternatives

High-Volume Packing Lines

If manual folding slows down fulfillment, a pre-glued crash-bottom tray or a machine-erected tray may be more efficient.

Standalone Parcel Shipping

Consider a corrugated mailer or a dedicated outer shipping carton if the tray will ship individually through a courier network.

Board, Print, and Assembly Choices

Board Thickness and Lock Fit

The locking tongues and receiving cuts are highly sensitive to material caliper. Changing from a standard folding carton board to a thicker micro-flute requires recalculating the fold clearances to prevent the walls from bowing.

Print Surface Planning

Because the inner walls fold completely over, the interior of the assembled tray displays the front (coated) side of the board. This allows for continuous high-quality graphics inside and out without requiring two-sided printing.

Assembly Labor

The multi-step folding sequence provides a premium result but requires dedicated manual labor. Packers fold the outer walls, trap the corner flaps, and seat the locking tongues into the base cuts.

Insert and Partition Compatibility

If the tray will hold multiple items, decide whether to use a folded paperboard insert or a molded tray. The double-wall sides provide a rigid perimeter to hold inserts securely.

Structural Adjustments for Fit

Locking Tongue Offsets

The depth and position of the locking tabs can be adjusted to ensure a secure friction fit based on the specific board grade chosen.

Panel Height and Clearance

The inner folding panels are slightly shorter than the outer walls to accommodate the board thickness when folded flat.

Base Proportions

The length and width can be adjusted to fit specific shelf depths or to match the footprint of an outer sleeve.

Packing details

Flat Delivery and Storage

The unglued cross-shaped blank ships completely flat, maximizing pallet density before use.

Corner Flap Tapering

The internal corner flaps are angled to prevent binding when the inner walls fold over them, ensuring a square, rigid corner.

Additional notes

Board thickness and locking cuts

The friction locks depend on exact material thickness. If the board grade changes between prototyping and production, the cut depths and fold clearances should be updated to ensure the tray stays locked.

FAQs

Does this tray require glue or tape to stay together?

The tray relies on a sequence of folds and friction locks. The inner walls fold over corner flaps, and hidden tongues slot into cuts at the base to hold the shape securely.

How is this tray typically assembled?

This specific unglued structure is typically erected by hand at the packing station, though specialized plunging mandrels exist for some roll-end trays.

Do I need two-sided printing to have graphics on the inside of the tray?

Because the side walls fold 180 degrees over themselves, the front (print side) of the board becomes the visible interior of the tray walls. The base floor, however, will show the back of the board unless printed.

Can I use a thicker corrugated board for this template?

Switching to corrugated board is possible but requires precise structural adjustments. The 180-degree folds and locking cuts must be recalculated for the thicker caliper to prevent the board from cracking or the locks from failing.

Can this tray ship individually through a courier network?

Because it is an open-top tray, it usually requires an outer shipper, mailer, or secure sleeve if it will be shipped individually through a courier network.

How does the double-wall construction affect internal space?

The folded walls consume a small amount of internal footprint. When sizing the tray for a specific product or custom insert, the internal dimensions should account for the double board thickness on all four sides.

How are the trays delivered to the packing facility?

The unglued blanks are delivered flat, which helps maximize pallet density and storage space before assembly.

What happens if we change the board thickness after prototyping?

The friction locks and fold clearances depend on the exact material thickness. If the board grade changes, the cut depths and fold offsets should be updated to ensure the tray stays locked.