Custom Double Wall Tray
Loading a single wall tray with anything heavy teaches you why doubled walls exist. The sides bow outward, the corners soften, and within a day the whole thing looks like it has been through something. Folding the board back on itself solves that. We produce a lot of double wall tray work at ZEE Packaging and weight is what drives every specification here.
Two Layers On Every Side
A double wall tray folds the board back over itself.
- Each wall becomes two layers rather than one
- The tray holds its shape under a full load
- Corners resist crushing during transit and stacking
- Rims stay crisp through repeated handling
- It carries considerably more than a single wall
- The doubled edge looks finished from every angle
Most operators specifying a double wall tray have already watched a single wall version fail on a shelf.
Weight Sets The Threshold
There is a clear point where this becomes necessary.
- Glass jars and bottles, which concentrate load
- Canned and tinned product ranges
- Trays stacked two or three high
- Long campaigns where a unit sits out for weeks
- Anything handled repeatedly by store staff
- Unnecessary for sachets, cards and light goods
- Open double wall tray the standard build we run
- With a removable lid shipping sealed then opening
- Front cut down version product visible from the front
- Tiered stepped format rows visible behind the front
- Divided tray compartments for several SKUs
- With a header card branding above the unit
Sizes We Print Regular
Every double wall tray is built to your product, though these run often:
- 10" x 8" x 4" for a standard counter unit
- 12" x 9" x 5" for a larger display
- 14" x 10" x 5" for a heavier range
- 8" x 6" x 3" for a compact tray
- 16" x 12" x 6" for a bulk display
- 18" x 12" x 6" for a floor level format
Send us the loaded weight, since that is the entire reason for this construction.
Board And Print
- B flute corrugated as the baseline for doubled walls
- C flute where more cushioning matters
- True double wall board for genuinely heavy freight
- Litho laminated corrugated for full color retail print
- Kraft corrugated for a plain economical build
- Printed inner walls, visible as product sells through
The terminology confuses people, so worth being clear. This folds the board twice, whereas double wall board is a different material with two flutes inside it.
Materials Worth Choosing
- Recycled corrugated, standard across these grades
- FSC certified board, certificate available on request
- Soy based ink through the whole run
- More board used, though the unit lasts a full campaign
- No lamination, so it recycles at end of life
- Right sizing so you ship product rather than air
What Working With Us Involves
- 100 unit minimum, so a small brand can test the format
- Free 3D mockup and flat proof before anything prints
- Free dieline drawn by our own designer
- Physical sample on request to test under real load
- Urgent turnaround at 5 to 8 business days
- Free shipping worldwide with nothing hidden
Frequently Asked Questions
Is it the same as double wall board?
No, though the names overlap. This folds the board twice, whereas double wall board has two flutes in the material itself.
How much stronger is it?
Noticeably on wall rigidity. A single wall bows outward under weight, whereas doubled walls hold square.
How much is a double wall tray?
Rough estimate is $0.80 to $2.00 per unit in plain corrugated, $1.30 to $3.00 with print and $2.10 to $4.60 for litho laminated at moderate quantity. Size moves it. Shipping is included in our price. This is estimate only, so ask our team for a exact quote.
Does it use more board?
Yes, since each wall is two layers. That buys you a tray that survives a full campaign rather than a week.
When is it overkill?
For light product like sachets or cards. Single wall handles those perfectly well at lower cost.
Does it assemble slowly?
Slightly, since there are more folds. It is still quick once staff have built a few.
Can it ship pre filled?
Yes, with a lid over the top. That protects product in transit and saves store labor.
