Double Wall Tray Boxes
A reinforced double-wall tray offering extra sidewall strength for weighty or delicate contents.
Structural & Engineering Details
How This Structure Works
A double-wall tray raises its sides in two thicknesses, giving an open tray extra sidewall strength for weightier or more delicate contents. The doubled walls resist bowing when the tray is filled, so the shape stays crisp and stacking is steadier. With an open top, the geometry favors visibility and easy loading while the reinforced edges add durability the single-wall version lacks. This can suit produce, bakery, or heavier retail items where the tray must hold its form under load and present neatly. Because the reinforcement is folded from the same blank, no separate liner is needed to firm up the walls.
Good Fit For
- Heavier produce or bakery items
- Open trays that must resist bowing
- Stacked display of filled trays
Key Advantages
- Doubled sidewalls resist bowing under load
- Open top keeps loading and viewing easy
- Reinforced edges steady stacking
Assembly & Construction
The side panels fold over to form a double thickness before the tray locks or glues square, so the walls gain rigidity from the folded layer. The open top needs no lid step, keeping assembly to squaring the base and setting the reinforced walls. Packers erect the tray, seat the doubled sides, and load from above, so the shape holds under an even fill without a separate stiffening insert.
Materials & Board Options
A heavier paperboard suits lighter reinforced trays, while corrugated grades are often chosen when contents are weighty or the tray must stack. The doubled wall benefits from a caliper that folds cleanly yet stays firm. Final board, any flute, and coating typically depend on the load, tray size, print, filling method, and handling in distribution, so a loaded sample usually confirms the right specification.
Pre-Production Planning Checklist
- Confirm the doubled walls resist bowing under your fill
- Check stacking stays steady with trays loaded
- Verify corner folds stay crisp at the double thickness
