Full Flat Double Tray Boxes.

A base tray and a lid tray, each cut flat and folded with locking corners, nest together into the silhouette of a two-piece rigid box. There's no chipboard and no wrapping, so it costs and ships like a folding carton.

The effect depends on fit. We hold the lid tolerance tight so it slides down with slight resistance, since a loose lid gives the game away.

Yes, a second tray sits on a ledge or spacer above the first, so the top layer's weight never rests on the items below. Finger notches or a ribbon lift let the customer raise the upper tray flat and level.

The tray board has to be stiff enough not to flex mid-lift. For confectionery, a glassine sheet between layers keeps the two apart.

Both trays leave us as flat die-cut blanks, and your packers fold each wall up and lock the corners by hand. No glue is needed at the edges, and freight and warehouse space drop to a fraction of what set-up boxes take.

We send a folding guide with the first run. After a short while at the bench, most packers erect them quickly.

The outside prints in CMYK, and the lid can be embossed or given a window. Inside, matched printing on both trays keeps the presentation continuous when the lid comes off and again when the top layer lifts.

For assortments, a printed layer map inside the lid names each position. We register the wells to that map so every piece lines up with its label.

Twin-tray builds commonly run from 10 x 7 x 2.5 inches to 14 x 10 x 4 inches. The depth covers both layers plus the ledge, so it's a little more than twice the height of one layer of product.

Two layers fit the same count into half the footprint, which reads as generous on shelf. Send the item size and count per layer and we'll draw both trays.

We'll produce double tray boxes from 500 units. Both trays ship flat, so holding extra stock for a second season takes very little room. Seasonal assortments usually run well above that figure.

Adding a window lid, a food-safe coating or embossing on the lid doesn't change that starting quantity.

Our production window is 7 to 10 business days, shortened to 5 to 7 with rush. A flat sample of both trays reaches you in 5 to 7 business days, so your team can practise the fold and test the second-layer lift.

Once you confirm the order, the sample fee is subtracted from it.

We build them in food-grade paperboard, PE-coated kraft or greaseproof stock, with a compostable pulp option. PE coating and greaseproof paper keep grease and moisture from marking the board.

Uncoated paperboard and compostable pulp are the easiest to recycle or compost. A PE-coated tray needs a facility that accepts coated board, so we'd only specify it when the contents call for a barrier.