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EVF46010

Hexagonal 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

Rolled double walls hide raw edges
Glue-free manual assembly
Pairs with a separate lid, sleeve, or wrap

About this product

The EVF46010 is a premium, six-sided paperboard tray that uses clever roll-end folds to create thick double walls with hidden edges. Designed for luxury retail, cosmetics, and confectionery, it locks together entirely through friction and base slots, avoiding the need for glue.

Because the inner panels roll completely over the top edge, no raw board edges are exposed. This creates a high-end presentation, though the complex flat blank and manual assembly make it a strong fit for projects where the unboxing experience justifies the extra packing time.

Common uses

Luxury cosmetics and skincare sets
Premium confectionery and chocolates
Specialty gift kitting
High-end apparel accessories

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Premium retail and gift presentation

Luxury cosmetics and skincare sets

The thick walls and clean top edge provide a high-end frame for bottles, jars, and cosmetic kits. Because the double walls hide the reverse side of the board, a single-sided print still delivers a premium interior.

Confectionery and specialty foods

Often used as the base for premium chocolates or baked goods. When paired with a clear sleeve or shrink wrap, the rigid hexagonal shape protects the contents while maximizing visibility.

High-end apparel and accessories

Useful for presenting rolled ties, belts, or scarves. The lack of raw edges prevents snagging on delicate fabrics while elevating the perceived value of the product.

Specialty gift kitting

A strong choice for curated corporate gifts or holiday bundles. The six-sided shape stands out on a display table, and the double walls provide enough rigidity to hold multiple small items securely.

Fulfillment and kitting realities

Hand-packed kitting operations

This tray ships flat and bypasses the folder-gluer, but it relies on a specific four-step manual folding sequence. Packing teams fold the primary walls, roll the secondary panels over the corner webbing, and snap the tabs into the base. It is highly effective for dedicated kitting lines but not suitable for automated tray erectors.

Premium retail display

In boutique environments, the unboxing experience is part of the product. The hidden edges and thick walls give the tray a substantial feel that matches high-end retail expectations.

Limited edition product launches

For short-run or seasonal promotions, the lack of gluing setup can make this tray an attractive option, provided the manual assembly labor is factored into the fulfillment plan.

When to consider a different tray style

High-volume automated packing

If your fulfillment line relies on automated tray formers or needs instant pop-up assembly, a standard four-corner glued tray or an auto-bottom design will be much faster than this manual roll-end structure.

Heavy industrial or parcel shipping

This is a presentation tray, not a shipping container. If the tray itself will be shipped individually through parcel networks, or if the product is exceptionally heavy, consider corrugated alternatives that offer higher crush resistance.

Board choice and production route

Board grade and fold quality

The locking mechanism relies on panels rolling 180 degrees over the corners. This often points to a high-quality folding boxboard (FBB) or solid bleached board (SBS) that can handle tight folds without cracking. Recycled boards with shorter fibers may split along these critical hinges.

Blank sprawl and material efficiency

The flat blank for a double-wall hexagon is highly irregular. It does not nest as tightly on a printing sheet as a standard rectangular tray, which increases the overall material footprint. Discussing the exact dimensions early helps optimize the sheet layout.

Print surface and interior presentation

Because the inner walls roll over to cover the interior perimeter, the unprinted back of the board is hidden. A single-sided print will display on both the outside and the inside walls, which can reduce printing costs for premium designs.

Closure and lid strategy

As an open tray, this structure needs a secondary component for closure. Buyers typically pair it with a custom hexagonal slip lid, a clear plastic sleeve, or a tight shrink wrap to secure the items for retail display.

Adjusting the hexagonal footprint

Customizing the hexagon proportions

While typically produced as a regular hexagon with equal sides, the template can be adjusted to create an elongated or irregular six-sided footprint to better fit specific product arrangements.

Locking tab configuration

For larger trays, the number of locking tabs on the secondary walls can be increased to ensure the long panels stay securely anchored to the base.

Wall height and depth adjustments

The tray depth can be modified to accommodate taller products. However, deeper walls need a larger flat blank and change the leverage needed to roll the inner panels over the corners during assembly.

Packing details

Die-cutting and stripping complexity

The irregular perimeter of the flat blank requires careful die design to ensure clean stripping of the waste material. Discussing the exact dimensions early helps optimize the sheet layout and reduce the material footprint.

Additional notes

Board thickness and fold cracking

Because the inner panels must roll completely over the corner flaps, selecting a board with excellent folding endurance helps prevent issues. Brittle or overly thick boards may crack along the top rim, damaging the premium presentation.

FAQs

Does this tray need glue or tape to assemble?

The tray locks together entirely through friction and carefully placed tabs that snap into the base panel. It avoids adhesive, making it a clean option for hand-packing lines.

Can this tray be set up by automated machinery?

This specific roll-end structure is designed for manual assembly. The sequence of folding the corner webbing and rolling the inner panels into place is difficult for automated tray erectors to replicate.

Can this be made from corrugated board?

This exact template is engineered for paperboard. The tight 180-degree folds needed for the double walls may bind or crack if attempted with thicker corrugated material. For a fluted version, a dedicated corrugated template is a better starting point.

Do I need to print on both sides of the board?

Because the inner walls roll completely over and cover the interior perimeter, the unprinted back of the board is hidden. A single-sided print will display on both the outside and the inside walls of the tray.

Is this tray suitable for ecommerce shipping?

It is an open presentation tray. For parcel delivery, it should be placed inside a secure outer shipping box with appropriate void fill to protect the tray and its contents.

Does the tray come with a lid?

This template covers the base tray only. Depending on your retail strategy, you will need to specify a matching paperboard lid, a clear sleeve, or another closure method to secure the product.

Can I order this tray with a custom depth?

The tray depth can be adjusted, but deeper walls need a larger flat blank and may change how easily the inner panels roll over the corners during assembly.

What board grades fit this tray well?

High-quality folding boxboard (FBB) or solid bleached board (SBS) is often chosen because these grades can handle the tight 180-degree folds without cracking along the top rim.