Custom Full Flat Double Tray
Two trays cut from one sheet, hinged together so one folds over the other. That is the whole idea. You get a base and a lid that cannot be separated, both built with the same doubled construction, and the whole thing lies completely flat until it is needed. We produce a lot of full flat double tray work at ZEE Packaging and the single piece build is what makes it practical.
Two Trays, One Sheet
A full flat double tray is cut and folded as one piece.
- Both trays come from a single die cut sheet
- They hinge together rather than being separate parts
- Nothing gets mismatched or lost in a stockroom
- One dieline covers the entire structure
- It lies completely flat before assembly
- Doubled walls on both halves for rigidity
Most operators choosing a full flat double tray want a lidded tray without managing two components.
Flat Storage Adds Up
Shipping and storing assembled trays costs more than people think.
- A flat sheet takes a fraction of the volume
- Inbound freight drops considerably as a result
- Warehouse space requirement shrinks the same way
- Two trays from one sheet means one SKU to hold
- Assembly happens where and when it is needed
- It reduces the risk of crushed stock in storage
- Standard full flat double tray the everyday build
- With locked corners both halves holding square
- Window version showing product through a die cut
- Deep format for taller products
- Divided version compartments in the base tray
- Food grade version for bakery and catering use
Sizes We Print Regular
Every full flat double tray is built to your product, though these run often:
- 10" x 7" x 2" for a shallow format
- 12" x 9" x 3" for a standard unit
- 8" x 6" x 2" for compact items
- 14" x 10" x 3" for a larger tray
- 8" x 8" x 3" for a square format
- 6" x 4" x 1.5" for small products
Send us the loaded height, since the upper tray is sized against the filled base.
Board And Print
- SBS C1S at 18pt to 24pt for retail formats
- E flute corrugated for lighter shipping applications
- B flute where the tray carries real weight
- Kraft board for a natural or bakery position
- Litho laminated corrugated for full color print
- Food grade certified stock where food is involved
Board choice matters more here than on a single tray. The hinge between the two halves flexes every time it opens, so we specify stock that tolerates that.
Materials Worth Choosing
- Recycled board and corrugated, standard in these grades
- FSC certified stock, certificate available on request
- Soy based ink through the whole run
- One sheet rather than two separate parts
- Flat storage, which cuts transport volume considerably
- Right sizing so no board is wasted per unit
How An Order Runs Here
- 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 the fold and fit
- Urgent turnaround at 5 to 8 business days
- Free shipping worldwide with nothing hidden
Frequently Asked Questions
Why one sheet rather than two trays?
Because nothing gets separated. Two piece sets end up mismatched in a stockroom, which wastes stock over time.
Will the hinge crack?
Not with the right board and scoring. Cracking happens when heavy stock is folded on a shallow score.
How flat does it ship?
Completely, as a single sheet. Freight and storage volume drop considerably against assembled trays.
How much is a full flat double tray?
Rough estimate is $0.45 to $1.20 per unit in plain board, $0.75 to $1.90 with print and $1.30 to $3.00 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.
Can it hold food?
Yes, in food grade stock. It works well for bakery and catering applications.
How fast does it assemble?
A few seconds for both halves. Locked corners fold first, then it is ready to fill.
Can we add a window?
Yes, usually in the upper tray. It works well where the product sells on appearance.
