Custom Roll End Tray
The roll end construction takes a flat sheet and rolls the board around at each end to form doubled side walls. That single move gives you rigidity a plain folded tray never achieves, using the same amount of board. It is the base structure behind most mailer boxes for exactly that reason. We produce a lot of roll end tray work at ZEE Packaging and the rolled walls do all the work.
Rolled Rather Than Folded
A roll end tray builds strength into its own sides.
- The board rolls around to form each side wall
- That gives double thickness without a second sheet
- Walls stay vertical rather than pushing outward
- No glue or tape is needed anywhere
- It ships flat and forms in a couple of seconds
- The rolled edge looks finished rather than cut
Most operators choosing a roll end tray want rigidity without a glued or reinforced build.
Where It Fits Best
The format suits certain applications particularly well.
- Ecommerce mailers, where it is the standard base
- Retail trays that need vertical walls
- Gift packaging with a sleeve over the top
- Anything shipped without an outer carton
- Products that need a snug fit rather than filler
- Not ideal for very heavy loads, where glue holds better
- Open roll end tray the standard build we run
- With a tuck front becoming a mailer box
- With a separate lid shipping sealed then displaying
- With a sleeve the tray sliding out like a drawer
- Front cut down version product visible from the front
- With a die cut insert holding contents steady
Sizes We Print Regular
Every roll end tray is built to your product, though these run often:
- 8" x 6" x 2" for a standard format
- 10" x 8" x 3" for a mid size product
- 12" x 9" x 2" for apparel and flat goods
- 6" x 4" x 2" for small items
- 14" x 10" x 4" for larger orders
- 9" x 6" x 1.5" for a slim format
Send us the filled weight, since the rolled walls are specified against it.
Board And Print
- E flute corrugated for lighter contents
- B flute where the tray carries real weight
- Kraft corrugated for a plain, low cost build
- White corrugated where you want brighter print
- Litho laminated for full color across the surface
- One color flexo, the cheapest branded route
Interior print earns its cost on this format. The rolled walls and base are fully visible once the tray is open, which is what customers photograph.
Materials Worth Choosing
- Recycled corrugated, standard across these grades
- FSC certified board, certificate available on request
- Soy based ink through the whole run
- No adhesive at all in the construction
- Paper void fill rather than plastic
- Right sizing so you ship product rather than air
How An Order Runs With Us
- 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 walls loaded
- Urgent turnaround at 5 to 8 business days
- Free shipping worldwide, including to your fulfillment center
Frequently Asked Questions
How is it different to a plain tray?
The board rolls around to double each side wall. A plain tray has single thickness sides that splay under load.
Does it need glue?
No. The rolled construction holds itself, which is the point of the design.
How fast does it assemble?
A couple of seconds. It forms as you push the sides up, with nothing to tuck or lock separately.
Can it become a mailer box?
Yes, by adding a tuck front. That is the standard ecommerce mailer construction.
Will it hold heavy products?
Reasonably, though a glued tray holds better. Send us the weight and we will advise honestly.
How much is a roll end tray?
Rough estimate is $0.30 to $0.85 per unit in plain kraft, $0.50 to $1.30 with one color print and $0.85 to $2.10 for full color at moderate quantity. Size moves it. Shipping is included in our price. This is estimate only, so ask our team for a exact quote.
Should we print the inside?
We would recommend it. The rolled walls and base are all visible once the tray is open.
