Variation

1 / 3

EVF41180

Tapered Gusset 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.

Get pricing

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

Product details

Top highlights

Continuous webbed corners help prevent bottom leaks
Delivered flat for manual, glue-free assembly
Tapered walls prioritize presentation over stacking strength

About this product

The tapered gusset tray is a one-piece, unglued carton featuring flared walls and an integrated lid. Because the corners are webbed and folded inward rather than cut, the base forms a continuous tray that naturally resists dry and semi-viscous leaks, making it a frequent choice for bakery, takeout, and specialty retail.

Delivered completely flat, this style relies entirely on manual assembly at the packing station. While the tapered shape offers an excellent unboxing presentation, it reduces vertical compression strength, meaning these cartons are often chosen for individual handling or packing into larger master shippers rather than heavy pallet stacking.

Common uses

Bakery and pastry
Deli and takeout
Gift and apparel kitting
Specialty retail and cosmetics

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?

Bottom length

Bottom width

Interior height

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 type of product will go inside?

How will these be packed for shipping or delivery?

Where will these trays be assembled?

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?

Bakery, Takeout, and Retail Presentation

Bakery and Pastry

The continuous, uncut base helps keep crumbs and powders contained. When produced with a poly-coated board, it handles frosted or greasy items well without leaking through the bottom corners.

Deli and Prepared Foods

The webbed corners prevent thick sauces or semi-viscous liquids from escaping through the bottom, making it a frequent choice for takeout meals and deli counters.

Gift and Apparel Kitting

The flared walls create an inviting presentation when the lid is opened. The unglued, fold-together design provides a clean interior without visible adhesive seams, fitting premium retail environments.

Specialty Retail and Cosmetics

The tapered shape offers a distinct silhouette on the shelf, while the integrated lid provides a complete enclosure for multi-item sets or delicate retail goods.

Manual Packing and Flat Storage

Store-Floor and On-Demand Assembly

Because these trays require no gluing equipment, they can be stored flat in tight retail or kitchen spaces and erected by staff exactly when needed. The assembly process involves folding the walls up while pinching the webbed corners inward.

Limited Storage Environments

The flat-shipping format maximizes pallet density for incoming deliveries. Additionally, partially assembled bases can be nested inside one another to save space on a busy packing counter before the lids are closed.

Premium Unboxing Experiences

The angled walls naturally present the contents outward to the user upon opening, enhancing the visual impact of the packed items compared to a straight-walled box.

When to Consider Straight-Wall or Glued Trays

Heavy Stacking and Transit

Tapered walls offer limited vertical support. If the carton will bear significant vertical weight on a pallet or ship through a mixed-carrier parcel network without an outer shipper, a straight-walled corrugated box or a rigid glued tray is often a safer choice.

High-Speed Automated Packing

The complex inward fold of the webbed corners is difficult to mechanize. Operations relying on automated carton erectors should evaluate standard four-corner glued trays that open quickly on the line.

Board Thickness, Coatings, and Taper Angles

Board Caliper and Folding Endurance

The webbed corners fold 180 degrees flat against the interior walls. If the chosen board is too thick or lacks folding endurance, the corners may crack or create excessive bulk, which can interfere with lid closure. Standard folding boxboard (FBB) is usually preferred over heavy micro-flutes.

Moisture and Grease Barriers

While the physical structure resists dry leaks, the paperboard itself should be specified with the correct PE, PLA, or aqueous coating if it will contact greasy or wet foods.

Taper Angle and Internal Volume

The angle of the flared walls changes the presentation effect. A steeper taper increases the visual flare but reduces the usable internal volume and further limits stacking strength.

Closure Friction and Handling

The width and depth of the tuck tongue, along with the receiving slit, can be calibrated to the specific board thickness to ensure the lid stays closed during handling without tearing the flap.

Template Adjustments and Clearances

Wall Taper Adjustments

The template allows for different top and bottom dimensions, which dictates the angle of the walls and the geometry of the corner gussets.

Layer Step Creasing for Thick Boards

When heavier materials are necessary, the template can incorporate a step crease at the lid hinge. This allows the main lid to overlap the inner dust flaps smoothly without bowing under tension.

Tuck Tongue and Slit Calibration

The closure mechanism can be adjusted for tighter or looser friction depending on how frequently the end user will open and close the tray.

Packing details

Interior Space Reduction from Gussets

The webbed corners fold inward and rest against the interior walls, slightly reducing the usable width and length at the corners. This should be accounted for when sizing rigid inserts or square products.

Grain Direction Planning

Aligning the board grain with the main lid hinge and the primary gusset folds helps prevent cracking and ensures a smoother manual assembly process.

Lid and Flap Configurations

EVF41180 (Standard)

Features a single full-coverage hinged lid with a tuck tongue, supported by three inner dust flaps.

EVF41180a (Overlapping Lid)

Replaces the full lid with two major overlapping top panels and two minor dust flaps, changing the closure style and the geometry of the corner folds.

Additional notes

Nesting empty trays

Because the walls are tapered, partially assembled bases can be nested inside one another to save space on a busy packing counter before the lids are closed.

FAQs

Can this tray be erected by automated machinery?

Generally, no. The webbed gussets require a simultaneous upward and inward folding motion that is designed for manual assembly at a packing station.

Is the continuous base completely liquid-tight?

The uncut corners prevent dry goods and thick liquids from leaking through gaps. However, true liquid-tight performance depends entirely on applying a waterproof coating or film to the board itself.

Can we use corrugated micro-flute for this design?

It is rarely recommended. The corner gussets fold completely flat against the walls. Corrugated material creates too much bulk when folded 180 degrees, which distorts the tray and prevents the lid from locking.

Can this carton be shipped through parcel networks?

Not on its own. The tapered walls and friction-fit lid are designed for presentation and local handling. Parcel shipping usually involves placing this carton inside a protective corrugated outer shipper.

Does this carton require tape or glue to stay together?

No. The corner gussets lock over the wall edges, and the top secures with a mechanical tuck-and-slit lock. No adhesive is needed for assembly.

Will the corners crack when folded?

Cracking is a risk if the board is too thick or has poor folding endurance. Specifying a high-quality folding boxboard and ensuring the grain direction aligns properly with the main folds helps prevent this issue.

Does the webbed corner affect interior printing?

Yes. Because the corner gussets fold inward and rest against the interior walls, they will cover portions of the inside panels. Artwork should be planned accordingly.

How does the tapered shape affect product fit?

The base footprint is smaller than the top opening. Square or rigid items should be sized to fit the bottom dimensions, while flexible or loose items can utilize the expanding volume of the flared walls.