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EVF41176

Leak-Resistant Gusset Tray with Attached 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.
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Product details

Top highlights

Webbed corner gussets prevent crumb and liquid leaks
Delivered completely flat with no pre-glued seams
Tray walls lock into place only when the lid is closed

About this product

This one-piece folding carton combines a leak-resistant webbed base with an attached telescoping lid. Designed entirely without glue seams, it is delivered flat to save space and is erected by hand at the point of sale, making it a practical fit for bakeries, cafes, and retail takeout counters.

The defining feature of this package is its reliance on the lid for its shape. The tray's webbed corners fold inward to contain crumbs and viscous liquids, but the walls remain flexible until the rigid lid is closed over them, locking the entire package into shape.

Common uses

Bakery and pastry takeout
In-store retail fulfillment
Food service requiring grease resistance (with coated board)

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Retail, bakery, and food service packing

Bakery and pastry takeout

The continuous base and webbed corners keep crumbs, glazes, and thick liquids contained. Because there are no cuts or open seams at the bottom corners, messy food items are less likely to leak during transport.

On-demand retail packing

The glue-free design means the box is delivered and stored completely flat. This requires minimal storage space behind a counter, allowing retail staff to keep high quantities on hand and fold them around the product only when needed.

Deli and catering orders

For heavier food items or orders with thick sauces, the webbed corners provide an effective barrier. The attached lid ensures the package can be closed quickly without searching for a separate cover.

Apparel and gift boxing

Beyond food, the clean interior and flat-storing nature make this a practical choice for retail gift packing. The telescoping lid provides a premium unboxing experience without the cost of a rigid setup box.

Store-floor storage and seasonal fulfillment

Store-floor storage and cafe fulfillment

Staff can store hundreds of flat blanks under a counter and fold them quickly without dealing with the bulk of pre-glued boxes. The manual assembly is straightforward, though it does require folding the lid locks and corner gussets by hand.

Food service requiring grease resistance

When specified with a poly-coated or grease-resistant board, the continuous corners provide an effective barrier against grease and moisture, making it practical for fresh food takeout.

Low-volume or seasonal packing

Because this template requires no folder-gluer setup at the factory, it is efficient for short runs or seasonal promotions. The entire carton is created through die-cutting and creasing.

When to consider pre-glued or independent trays

When the tray must stay rigid while open

Because this tray relies on the lid to hold the walls upright, loading heavy or complex assortments before closing the box can be difficult. If you need the tray to stand rigidly on its own during a multi-step packing process, a 4-corner glued tray is worth reviewing.

When packing lines are automated

This design requires manual folding of the 180-degree lid locks and corner gussets. High-volume automated lines should evaluate machine-erected tray styles that do not rely on complex manual friction locks.

Board stiffness, coating, and ventilation choices

Board caliper and fold resistance

The lid relies on a 180-degree roll-over lock, and the corners fold to 135 degrees. Heavy or stiff boards can resist these manual folds and cause the locks to fail or the board to crack. Standard folding boxboard (FBB) or solid bleached sulfate (SBS) usually performs better.

Coating and barrier requirements

While the webbed corners prevent physical leaks, the paperboard itself will absorb moisture and grease. If packing wet foods, specify a poly-coated or grease-resistant barrier.

Ventilation needs

The front wall includes optional cutouts to allow airflow for warm baked goods, preventing condensation buildup. These can be removed from the template if a completely enclosed presentation is preferred.

Print coverage and lid overlap

The 180-degree roll-over flaps on the lid will expose the unprinted inside of the board along the inner rim. If a uniform color is required inside the lid, two-sided printing must be specified.

Lid depth, corner webs, and ventilation

Lid depth and overlap

The depth of the telescoping lid can be adjusted to cover more of the tray wall. A deeper lid changes the visual profile and increases the friction grip that holds the box together, though it must remain shallower than the overall box height to close properly.

Gusset web width

The size of the inward-folding corner webs can be modified. This ensures they lay flat against the interior walls without interfering with the product inside the tray.

Front-wall ventilation holes

The circular cutouts on the front panel can be resized, repositioned, or removed entirely depending on whether the product requires airflow or a sealed environment.

Packing details

Print surface and interior visibility

The outside of the box is fully printable. However, the 180-degree roll-over flaps on the lid will expose the unprinted inside of the board along the inner rim unless two-sided printing is specified.

Parcel sealing and outer carton choice

The friction-locked lid and unglued walls are designed for hand-carry and retail presentation. Parcel or courier delivery will require packing this carton inside a dedicated corrugated outer shipper.

Additional notes

Flat delivery and retail storage space

Because this design uses no factory glue seams, it is delivered completely flat. This maximizes pallet density and allows retail staff to store high quantities in minimal space behind a counter.

FAQs

Does this box require glue or tape to set up?

The box is erected entirely by hand using friction locks on the lid and folding webbed corners on the base. It is delivered flat and requires no factory gluing.

Will the tray stay open on its own while I load the product?

The tray walls do not have independent locks. They will naturally splay outward until the rigid lid is folded over them to secure the shape. This can actually make loading wide items easier, but it means the box cannot be moved easily while open.

Can this box hold liquids or greasy foods?

The webbed corners prevent leaks through the seams, making it excellent for crumbs and thick glazes. However, for wet or greasy foods, you must specify a poly-coated or grease-resistant board.

Is this box secure enough for parcel shipping?

The friction locks and unglued walls are designed for retail hand-carry. Sending this through a courier network requires packing it inside a corrugated outer shipper.

Can I use a heavy corrugated board for this design?

Thick corrugated board will resist the required 180-degree folds and make manual assembly very difficult. Standard folding boxboard or solid bleached sulfate usually performs better.

Where can I place graphics on this box?

The entire exterior is available for printing. Keep in mind that the lid's side flaps fold over themselves, so the inside of the board will be visible on those inner edges unless you print on both sides.

How does the lid stay closed without tape?

The lid uses a friction lock. The side flaps fold over 180 degrees to trap the front tabs, creating a rigid rim that telescopes tightly over the tray walls.

Can I remove the holes on the front panel?

The circular cutouts are optional ventilation features for warm baked goods. They can be removed from the template if you prefer a completely enclosed box.