Trays are the most flexible structure in packaging and the most commonly mis-specified, because two numbers get confused: the outside footprint, which determines what fits in a shipper, and the inside clearance, which determines what fits in the tray. Board thickness sits between them, and on small trays that thickness is a meaningful proportion of the internal space.
The three numbers on every tray
- Footprint. Length by width, measured at the outside of the walls.
- Wall height. How deep the tray is, measured internally from the base to the top edge.
- Clearance. The gap between your product and the walls, which stops the product wedging and lets it be lifted out.
When you send us dimensions, send the product's dimensions and let the dieline be drawn around them. Design support is included, and this is precisely the case where working from the product rather than from a desired box size prevents a re-tool.
Choosing a wall height
| Wall height | Typically suits |
|---|---|
| Shallow, around an inch | Flat goods: cards, documents, thin samples, single-layer confectionery |
| Medium, around two inches | Most retail and gift contents, and trays used with a sleeve |
| Deep, three inches or more | Bottled, jarred or stacked contents, and trays that carry an insert |
Measure the tallest single item, then decide whether it should sit below the wall line or stand proud of it. Standing proud is fine with a deep lid and a problem with a sleeve.
Tray and lid, or tray and sleeve
A tray with a separate lid gives full coverage and protects the contents on all sides. The lid needs its own tolerance so it slides on without scuffing, which is the same clearance question covered on two piece boxes. A tray with a printed sleeve costs less, ships flatter and leaves the ends open, which is either a display advantage or a dust problem depending on the product. One tray size with several sleeve designs is the cheapest way to run a product range.
Trays as inserts
Trays are also used inside other boxes, seating products in a fixed position. In that role the critical measurement is the cavity, not the tray outline, and the tray has to be drawn to fit the interior of the outer box after its own board thickness is accounted for. See insert tray dimensions and insert packaging.
Board and structure
Shallow trays in light board flex under load and the corners are the first thing to fail. If the tray carries weight, the two options are a heavier caliper or a locking corner structure that reinforces where the walls meet. Tell us the loaded weight and it will be specified on your quote rather than assumed.
How to order a custom tray
The minimum is 100 units per size and artwork. Bulk pricing starts from about $0.48 per unit, confirmed in writing. The cutting die, the printing plates, design support, US shipping and a digital proof are included. Turnaround is quoted per product across rush (expedited production plus air freight, roughly 7 to 25 percent more), standard (air) and cost saver (sea), from about 7 business days of production plus 2 to 5 days for delivery, with specialty imported items up to about 12 weeks.
Send your product dimensions and loaded weight through the quote form and ask for the tray and lid and the tray and sleeve versions to be priced side by side.
