Double Wall Tray

Double Wall Tray: Strong Sides, Open-Top Access

A double wall tray is an open-top folding carton structure with side panels folded back on themselves to create two layers of board around key walls. This reinforcement helps the tray retain its shape during loading, handling and presentation while keeping the product accessible from above.

The format can work as standalone presentation packaging, an inner tray or the base of a multi-component pack. It sits alongside other reinforced and locking trays in our packaging box styles library.

When Should You Choose a Double Wall Tray?

This structure makes sense when a conventional tray is too flexible but a fully enclosed carton is unnecessary. Typical applications include:

• Confectionery and bakery products
• Cosmetics and skincare sets
• Gifts and promotional kits
• Clothing and accessories
• Small electronics
• Stationery
• Homeware
• Retail presentation packs

The open top gives packing teams direct access to the full tray area. This can be particularly useful for products that need careful positioning or are packed into an insert. For products requiring both a reinforced tray and separate cover, double wall tray lid boxes extend the concept into a two-component enclosed format.

Double Wall Cardboard Trays with Extra Board Layers

During erection, extended side panels fold inward to create additional layers of board along the tray walls. Depending on the dieline, locking tabs, folded sections or glued areas may keep these panels in position.

The resulting double wall cardboard trays generally offer greater edge rigidity than comparable single-wall folding trays. That does not automatically make them suitable for every heavy product; board specification, tray dimensions and load distribution still determine performance.

An angled double wall glued tray is a related configuration where glued construction and wall geometry may be used to achieve a particular presentation or structural requirement. The exact specification should be confirmed from the dieline rather than relying on the style name alone.

Double Wall Tray vs Foot Lock Tray

Both are open tray structures, but they solve different requirements. A foot lock tray uses mechanical locking tabs to secure the structure during assembly. A foot lock double wall tray can combine locking features with reinforced folded walls where the dieline calls for both.

Choose based on the actual priorities:

• Double walls when side and edge rigidity matter
• Foot locks when mechanical assembly is important
• Auto-bottom construction when erection speed is the priority
• A lid when the product needs greater enclosure

For faster tray erection, an auto bottom tray uses a pre-glued base that forms as the structure is opened.

Can a Double Wall Tray Be Used with a Sleeve?

Yes. A tray can be paired with an outer sleeve where the product needs more enclosure, additional printable area or a different opening experience.

A double glued side wall tray and sleeve arrangement should be developed as a complete system. Clearance between the tray and sleeve is particularly important: too tight and the components can bind; too loose and the assembled pack may feel poorly fitted.

Where two separate tray-shaped components are preferred instead, a full flat double tray provides another presentation-led structure worth comparing.

Double Wall Trays: Confirm Weight, Depth & Stacking

For a double wall tray UK project, start with the actual packed product rather than selecting dimensions from the external appearance alone.

Confirm:

• Product length, width and height
• Total packed weight
• Required tray depth
• Loading and removal clearance
• Wall and corner construction
• Need for inserts or partitions
• Whether a sleeve or lid is required
• Stacking and handling conditions

A physical sample is particularly useful for checking wall rigidity, product fit and whether the tray remains square after loading.