A tray pack is a packaging solution where products are secured in specifically designed trays which are then packed into secondary cartons or display boxes. Tray packs are widely used for shipping, retail presentation, and internal product organization.
Typical tray pack components
- Thermoformed tray: custom cavities for each SKU.
- Secondary carton: printed corrugated box or retail-ready carton.
- Protective layers: foam, interleavers, or films if needed.
Benefits of tray packs
Tray packs provide exact fit protection, faster packing/unpacking, better inventory handling, and improved presentation on retail shelves. They reduce product movement and damage, lowering return rates and transport losses.
Applications
Common in electronics (component trays), food (portion trays), medical devices (sterile tray packs), and automotive components where parts are precisely located for assembly.
Design considerations
- Material choice: rPET, PP, or FDA-grade plastics depending on product.
- ESD requirements for electronic parts.
- Stacking and nesting features to improve palletization.
Conclusion
Tray packs are a proven, efficient packaging method that combines protection and presentation — ideal for manufacturers seeking to reduce damage and improve supply chain efficiency.