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EVF41082

Two-Piece Gusseted Tray with Lid

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

Continuous webbed corners prevent bottom leaks
Double-wall tray sides lock into the base
Separate friction-fit lid for premium presentation

About this product

This two-piece folding carton pairs a continuous-corner bottom tray with a separate friction-fit lid. Instead of cut corners that can leak, the tray uses webbed gussets that fold inward and lock behind double-thick side walls, creating an unbroken base.

Delivered flat and assembled by hand without glue, it is a strong choice for bakery, catering, and premium retail presentations where containing crumbs, powders, or moisture is just as important as the unboxing experience.

Common uses

Bakery and pastry packaging
Catering drop-offs
Premium retail kitting
Cosmetics presentation

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Retail and Food Service Applications

Bakery and Catering

The unbroken bottom corners keep crumbs, powders, and viscous glazes contained. The double-wall sides provide enough rigidity to support heavier baked goods or dense catering portions.

Premium Retail Kitting

The separate lid and clean, rolled-over tray edges create a high-end presentation. The friction fit allows the lid to be removed and replaced smoothly, making it useful for gift sets or cosmetics.

Confectionery and Chocolates

For truffles or powdered sweets, the continuous bottom corners prevent fine particles from escaping, while the double-wall tray provides a sturdy frame for custom inserts.

Specialty Powders and Dry Goods

The webbed gussets eliminate the corner gaps found in standard trays, keeping fine dry goods securely inside the carton before the lid is removed.

Packing and Assembly Environment

Store-Level and Manual Packing

Because the tray and lid require no gluing equipment, they can be shipped flat and erected on demand at a retail counter or prep station. The foot-locks snap into place by hand.

Low-to-Medium Volume Runs

The manual assembly makes this carton highly accessible for short runs and regional rollouts, though it becomes labor-intensive for high-speed, automated fulfillment lines.

High-End Presentation Requirements

When the unboxing experience matters as much as containment, the separate lid and clean interior walls offer a premium feel without requiring glued joints.

When to Consider Alternative Tray Styles

High-Speed Automated Packing

If your operation relies on automated folder-gluers or case erectors, a crash-lock or straight-line glued carton will be much faster to erect than this manually folded gusset tray.

Heavy Transit or Courier Shipping

As a friction-fit two-piece carton, the lid can detach during rough parcel transit. For single-item e-commerce shipping, evaluate a mailer box with an integrated locking lid, or plan to use an outer shipping carton.

Board Flexibility and Lid Clearance

Board Flexibility and Cracking Risk

The webbed corners must fold 180 degrees inward during assembly. Highly recycled or very thick, brittle boards can crack along these tight folds. Discuss grain direction and board flexibility early.

Lid Friction and Clearance

The tightness of the lid depends on the exact board thickness and the clearance gap built into the template. A prototype should be tested to ensure the lid stays on without tearing the tray corners during removal.

Coatings for Food Contact

While the structure resists leaks, the material itself must handle the product. Greasy or moist foods will require specific poly or aqueous coatings on the inside of the board.

Print Surface and Finishing

Because the tray walls roll over to the inside, the interior walls display the same printed side of the board as the exterior, allowing continuous graphics without double-sided printing.

Template Adjustments

Tray Depth and Wall Taper

The height of the tray walls can be adjusted independently of the lid, and slight tapers can be introduced to change the visual profile or clearance.

Webbed Flap Angle

The geometry of the corner gussets can be modified to accommodate different board thicknesses, ensuring they fold flat without binding against the outer walls.

Lid Depth and Coverage

The lid can be configured as a shallow cover or extended into a full telescope design that reaches the bottom of the tray for added side-wall strength.

Packing details

Die Layout and Tooling

Because this is a two-piece design, the tray and lid can be nested on a single die board for smaller footprints, or run on separate dies to maximize material efficiency on larger press runs.

Additional notes

Grain direction and corner folds

Because the corner gussets fold diagonally, they will cross the board's grain regardless of orientation. Testing a physical sample helps verify that the chosen material and coating can handle these compound folds without cosmetic damage.

FAQs

Does this tray require glue or tape to stay together?

No. The tray walls roll over the corner gussets and secure themselves using foot-locks that press into slots on the base panel. The lid holds its shape through a similar friction-fit roll-end design.

Can this box be erected by automated machinery?

This specific structure is designed for manual assembly. The complex inward fold of the webbed corners and the roll-over locking sequence are difficult to automate on standard folder-gluers.

Is the bottom of the tray waterproof?

The continuous webbed corners prevent physical gaps where powders or thick liquids might escape. However, true waterproof performance depends entirely on selecting a board with the correct moisture-resistant coating.

What board types fit this design?

Flexible folding boxboards (FBB) or solid bleached boards (SBB) are usually preferred. The board must be able to handle tight 180-degree folds at the corners without cracking or splitting.

How tight is the lid?

The lid relies on a friction fit. The exact clearance gap is adjustable in the template, and it should be tested with a physical sample using your chosen board to ensure it is neither too loose nor too difficult to remove.

Can this be shipped as a standalone parcel?

Two-piece friction-fit boxes are generally a poor fit for direct courier shipping without an outer mailer, as the lid can detach. They are better suited for retail shelves, direct hand-offs, or packed inside a master shipper.

How does the foot-lock mechanism work?

The inner walls of the tray roll over the folded corner gussets, and small tabs at the bottom of these walls press into pre-cut slots on the base panel, locking the entire tray together.

Can I print on the inside of the tray?

Yes. Because the outer walls roll over to form the inner walls, the inside of the tray displays the same side of the board as the outside, allowing continuous branding without requiring two-sided printing.