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Double Wall Tray Boxes

★★★★★
4.5/5 15+ reviews Verified on Trustpilot
Bestseller Packaging Supplier

The structure of these double wall tray boxes is simple but effective. These include an inner container and outer box. The inner tray keeps the contents snug and the outer box provides additional protection. They are designed in simple, functional manner. They are cut from sturdy, recyclable corrugated cardboard. Double wall tray boxes are used for fragile items, including glassware and electronics. They are also used for office supply organisers, craft organisers, and kitchen utensil organisers.

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ISO Certified
FSC® Certified
Food Safe Materials
UK Based Manufacturing
Low Minimum Orders

Design Double Wall Tray Packaging Templates

Double wall tray boxes are among the packaging that provides more protection. They are great for transporting and packaging breakable or delicate goods. Double wall tray boxes are best known for security, organisation, and efficient use. Here, you will read a detailed workflow and a list of templates for double wall tray boxes design.

Types of Double Wall Tray Packaging Templates

Standard Double Wall Tray Box Template Type 1

This means that a standard double wall tray box is a common box type, but very customizable. The double wall construction and tray-style design for easy access. Double Wall Tray Box-The perfect box for packing and shipping small to medium items.

Custom Double Wall Tray Box Template Type 2

A double wall tray box is a template type of container that is designed for specific applications or industries and also a custom Double wall tray box. Its a double wall construction with a custom tray design to fill the special requirement of the goods stored. The 2-Tier Double Wall Tray box is ideal for unique or specialty items.

Lid double wall tray box Template 3

One is double wall tray box with lid which is template type that provides more protection and security. It consists of double wall, tray type and lid that allows easy access to the content. So, Double wall tray box with lid is the best way to store and move your valuable or delicate items.

Complete Design Process

Step 1: Dimensions and the material for your box

Decide the box dimension and its material for double wall tray box design. It includes taking into account the dimensions and weight of the products to be stored. The size of the box has to be considered in terms of length, width and height, as well as the thickness of the box walls and tray.

When selecting material, think about the durability and stoutness. Good options include corrugated cardboard or plastic. Consider any additional needs, like needing to be moisture resistant or static proof, too.

Step 2: Choose a Tray Design

The next stage is to select a tray layout that works for you. Among them: fixed or removeable tray, and adjustable.

The first thing that is important to take into consideration to choose a design of your trays is the size and shape of the product that has to be stored. You will also have to consider how practical the tray is and if it offers sufficient support and protection for the items.

Step 3: Choose how many compartments to include

Once you have designed the tray, the next step is to determine the number of compartments or the cells within the tray, and to set the location of them. This will vary based on the size and shape of the items to be stored and the needs of organisation and accessibility.

Based on how readily available the products are, cite the range of compartments/cells and their placement; After this, you also need to consider if the products are secure and supported in the compartments or cells.

Step 4: Incorporate Further Design Details

Add design elements Like logos, text, or images of any other kind. Which also can contribute to improve its design and appearance and provide useful information and branding, too.

When using these other design components, choose for readability and comprehension. You should also consider if they are giving enough information and branding.

Moreover, the box needs to be easy to open and close, and offer easy access to the contents too. Finally the box should be able to accommodate for logos, text, and images for branding and informational purposes.

Design Tools and Software

Probably the most helpful aspect of design tools and software are the design tools and software used to design a double wall tray box. These are CAD (computer-aided design) software, graphic design software, and packaging design software.

The software is used to design your box in detail and prepare a model. Software enables users to create and modify graphics, logos and text. Packaging design software lets you design and modify designs from box, double wall tray boxes.

Some Tips For Designing A Double Wall Tray Box

  1. Take into consideration the dimensions and weight of products.
  2. Select a material that is durable and strong.
  3. Make the contents easily accessible
  4. Include some design fields to customise and brand.

These are just some of the tips that you will need to use while designing double wall tray box.

Where to get Printed Double Wall Tray Boxes?

Choose Healey Packaging double wall tray box to serve all needs. Healey Packaging is your trusted partner backed by years of experience and expertise in designing and manufacturing custom packaging solutions. You can send us free quote request to make your own printed boxes. Send us email at help@healeypackaging.co.uk.

Dimension (L + W + H) All Custom Sizes & Shapes
Quantities No Minimum Order Required
Paper Stock 210gsm, 250gsm, 280gsm, 300gsm, 350gsm, 420gsm, 460gsm, 500gsm,
Bleach Card (SBS), Eco-Friendly Kraft, E-flute Corrugated, Bux Board, etc.
Printing No Printing, CMYK, CMYK + 1 PMS color, CMYK + 2 PMS colors
Finishing Gloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV,
Spot UV, Embossing, Foiling
Included Options Die Cutting, Gluing, Scoring, Perforation
Additional Options Eco-Friendly, Recycled Boxes, Biodegradable
Proof Flat View, 3D Mock-up, Physical Sampling (On request)
Turnaround 7 – 10 Business Days, RUSH
Shipping FLAT

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Explore Our Premium Packaging Options

Mix and match materials, printing methods, inks, finishes, and add-ons.

Strong Corrugated Cardboard

Corrugated Cardboard

Shipping • E-commerce • Heavy items
Fluted structure for strength and cushioning. Best for mailers, shippers, and products that need real protection in transit.
Durable Protective
Eco Natural Brown Kraft

Natural Brown Kraft

Eco brands • Food • Lifestyle
A warm, uncoated look that feels honest and natural. Great for bakery, subscription packaging, and earthy brand aesthetics.
Recyclable Natural look
Premium SBS / Bleach Card

SBS / Bleach Card

Beauty • Pharma • Retail
Bright white surface for sharp detail and clean colour. Ideal for premium cartons where print quality must stay crisp.
High print Clean white
Luxury Black Kraft / Black Card

Black Kraft / Black Card

Luxury • Gifts • Apparel
Deep matte stock that pairs beautifully with foil and minimalist branding. Built for premium shelf presence and gifting.
Foil-ready Premium look
Flexible Digital Print

Digital Print

Short runs • Variable designs
Fast setup, great for smaller quantities and designs that change frequently. Strong colour output without plate costs.
Low MOQ Fast
Classic Offset Print

Offset Print

Larger runs • Brand accuracy
Best for scale. Consistent results run after run, especially when brand tones and fine detail matter.
Sharp detail Cost-effective
Tactile Scodix Enhancement

Scodix Enhancement

Raised effects • Spot textures
Adds raised UV and tactile highlights to chosen areas. Ideal when packaging needs a premium touch people notice instantly.
3D feel Premium
Gloss UV Print

UV Print

Rich colour • Instant cure
UV-cured inks dry instantly and hold colour density well. Great for coated boards and vibrant retail graphics.
Vibrant Durable
Standard CMYK Process Inks

CMYK Process Inks

Full colour • Gradients
The go-to for full colour artwork, photography, and complex graphics. Great base before special effects.
Versatile Full colour
Branding Pantone Spot Inks

Pantone Spot Inks

Exact brand tones
When consistency is non-negotiable. Locks in signature brand colours across materials and runs.
Consistent On-brand
Bold Screen Printing

Screen Printing

Thick ink • Strong coverage
A heavier ink laydown for bold logos and high opacity. Great for darker stocks and simple, confident marks.
Opaque Vibrant
Eco Soy / Vegetable Inks

Soy / Vegetable Inks

Lower VOC options
A cleaner alternative often paired with kraft stocks and minimal design. A solid fit for eco-led packaging projects.
Low VOC Eco-minded
Matte Matte Lamination

Matte Lamination

Soft look • Low glare
Smooth, modern finish that reduces shine and improves scuff resistance. A favourite for premium cartons.
Premium Modern
Gloss Gloss Lamination

Gloss Lamination

Shiny • Eye-catching
Boosts vibrancy and protects print. Great when you want shelf pop and a brighter finish.
Shiny Protective
Tactile Soft-Touch Coating

Soft-Touch Coating

Luxury feel
Velvety, premium hand-feel that elevates unboxing. Best for luxury and gift packaging.
Velvety High-end
Highlight Spot Gloss UV

Spot Gloss UV

Logo & details
Gloss applied only where you want attention. Makes logos and patterns catch light without coating the entire box.
Contrast Logo focus
Luxury Foil Stamping

Foil Stamping

Gold • Silver • Custom
Metallic foil pressed into stock for premium impact. Perfect for logos, borders, and gift packaging accents.
Metallic Premium
Raised Embossing

Embossing

3D raised detail
Raises selected artwork for a tactile finish people feel immediately. Great for brand marks and patterns.
3D Texture
Depth Debossing

Debossing

Recessed detail
Pressed-in detail for subtle luxury. Works beautifully for minimal packaging where restraint looks premium.
Luxury Minimal
Windows Die-Cut Windows

Die-Cut Windows

Show the product
Custom window shapes that reveal the product. Can be open or backed with clear film depending on use.
Retail Product focus

Why Brands Trust Us

We are not just box manufacturers. We help brands package smarter, ship safer, and sell better, without unnecessary complexity.

  • Packaging Specialists Industry-focused structures, not generic templates.
  • Low MOQ Support Start small, scale confidently.
  • Material-First Engineering Right board, right strength, right finish.
  • UK & Global Fulfilment Flat packed, secure, and delivery-ready.

Our Process

01

Share your product size, quantity, and use-case.

02

We recommend structure, material, and finish.

03

Approve dieline or sample before production.

04

Manufacturing, quality check, and delivery.

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