Description
Custom Double Wall Trays That Hold the Load and Show the Product
Your product needs to be visible on the shelf, and the tray it sits in needs to hold up. Weak single-wall trays don’t do either job.
A thin-walled tray bows as soon as it’s loaded, tips when stacked, and looks defeated on the shelf next to a competitor’s clean display. Once one tray in a pallet stack fails, everything above it goes with it — crushed produce, broken retail units, a mess to clean up and a return to eat. Meanwhile, an unbranded brown tray does zero work to sell the product it’s holding.
Custom double wall trays from Hexa carry the load and merchandise the product at the same time. Reinforced double-thickness walls stay square under weight. The open top puts your product on show. And full-color printing turns the tray into shelf-ready branding.
What a Double Wall Tray Actually Is
A double wall tray is a one-piece, open-top tray where each side wall is built up with two layers of board instead of one. That doubled wall changes what the tray can do:
- Real load-bearing strength — resists bowing, crushing, and pallet stack pressure.
- Squared, stackable shape — the doubled walls keep the tray true through transit and handling.
- Open-top product visibility — no lid means the product sells itself on the shelf.
- Ships flat, builds fast — walls fold up and lock without glue in seconds.
It’s a workhorse for produce and bakery, meat and seafood, shelf-ready and PDQ retail displays, heavier bulk products, and industrial parts. It also works as a sturdy base for a separate lid or cover when your setup calls for one.
Where a Double Wall Tray Earns Its Keep
Choose this build when the walls have to work and the product needs to be seen.
| Use Case | Why It Fits | Suggested Material |
|---|---|---|
| Produce, bakery, meat & seafood | Strong walls handle weight and moisture with the right liner | B-flute corrugated |
| Shelf-ready / PDQ displays | Stackable, on-brand, ready to place | B-flute or E-flute corrugated |
| Heavier retail bulk products | Walls hold under weight without bowing | B-flute corrugated |
| Industrial parts & components | Rugged, stackable, glue-free | B-flute corrugated |
| Base for a separate lid/cover | Squared tray pairs cleanly with a fitted lid | B-flute corrugated |
Double Wall Tray vs. Other Tray Builds
Where this build fits in the wider tray family, honestly.
| Build | Construction | Best For |
|---|---|---|
| Single-wall open tray | One-layer walls, tucked or slotted | Lightweight retail, low stacks |
| Double wall tray (this build) | Doubled walls, glue-free corner lock, no lid | Heavier loads, stacking, open display |
| Double locked wall + lid | Doubled walls plus a matching lid | Enclosed premium retail, gift sets |
| Full-glued rigid tray | Glued, wrapped rigid chipboard | Luxury gifting only |
If you need the load-bearing walls and a matching lid, that’s our Double Locked Wall Lid Boxes — this page is for the open tray on its own.
Print That Turns the Tray Into Shelf-Ready Branding
An open tray puts the product on display. We finish the tray so it earns its spot on the shelf too.
- PMS spot-color matching and full CMYK for true-to-brand color
- Bold, appetizing print for produce, bakery, and retail
- Spot UV, foil, and matte finishes for premium retail trays
- Full-color printing on all four side walls — the panels shoppers actually see
Packaging Expert Tip: Spec for the Stack, Not Just the Single Tray
Here’s the mistake that turns a solid tray into a crushed one. Buyers spec the flute based on how one tray feels in the hand — but the tray isn’t holding one load, it’s holding whatever’s stacked on top of it. That’s called compression strength (ECT) and it’s the number that decides whether the bottom row survives the pallet.
Two moves that save you from a crushed shipment. First, spec for the stack height and total load, not the single tray — for shelf-ready and pallet stacks with real weight, that usually means B-flute and the right ECT rating for the load. Second, do a short stack test with real product weight before committing to a full run. Ten minutes of testing saves you a distorted display or a crushed bottom row across a whole order.
If you’re storing produce or refrigerated goods, ask for moisture-resistant stock — humidity will collapse untreated corrugated fast, no matter how strong the walls are.
What Every Hexa Order Includes
The same standards apply to every order, with no fine print to get there:
- No die or plate charges — zero hidden setup fees, ever.
- Low 100-tray minimum — test a placement or supply a full rollout on the same spec.
- 8–10 business day turnaround — your packaging is never the bottleneck.
- Free dielines — ready-to-use templates so artwork drops straight in.
- Free 24/7 expert support — real structural and print help, not a scripted bot.
- 100% recyclable materials — sustainable board your customers notice.
Get a Tray That Holds the Load and Sells the Product
Strong, glue-free, shelf-ready — one order away, shipping in 8–10 days. Send us your product weight, tray dimensions, and stack height and we’ll get you a quote, a free dieline, and a tray spec’d for the load the first time.
Get your free quote today — no setup fees, low 100-tray minimum, delivered in 8–10 business days.
- 👉 Request a Free Quote
- 📞 Talk to a packaging expert — free 24/7 support
- ✉️ Email us anytime: hello@hexacustomboxes.com
