Custom Packaging Knowledge Centre

7 Reasons to Use Cardboard Trays Belong in Your Packaging Strategy

Written by SmartShield | Jul 11, 2025 7:20:27 AM

At SmartShield, we’re always exploring the most effective ways to protect and move products, from custom crating to smart custom cardboard packaging solutions.

One standout option we’re seeing more of in warehouses and logistics plans is the custom cardboard tray. Simple? Yes. Sustainable? Yes. Surprisingly versatile? Also: yes!

Whether you're packing up robotics or managing multi-product shipments, here are seven reasons custom cardboard trays deserve a spot in your packaging lineup.

1. They’re Ideal for Large or Heavy Items

When a product is too big or bulky to be lowered into a box, a cardboard tray makes loading easier. The product is placed directly on the tray, and a sleeve or half-slotted container is then slid over the top—no lifting, no tipping, no problem. This tray and sleeve or box system is commonly used in industrial, robotics and medical packaging, where large items need secure but manageable containment.

2. They Work Seamlessly with Half-Slotted Boxes

Cardboard trays are often paired with half-slotted containers (HSCs) to create a tray and box system that’s efficient, easy to use, and great for larger items. This combo creates an easy-access box design that’s especially helpful for products that need to stay upright or be accessed quickly during packing.


3. They Support Multi-Product Pallet Shipping

Need to move multiple units on one pallet? Cardboard trays help organize and separate products during multi-packaging shipments, giving structure without excess material. They're lightweight, stackable, and compatible with most pallet systems.

4. They Make Unpacking Easier

One of the most practical advantages of using cardboard trays is how much easier they make access, especially with larger or multi-part shipments.

With traditional boxes, top flaps often get in the way during unpacking. But with a tray-style top, the cover lifts away cleanly, making it easier to access the contents and giving the packaging a cleaner, more professional look.

This is especially helpful when dealing with bulky or sensitive items such as medical equipment, where lifting a full box vertically isn’t always possible. In these cases, we often recommend pairing a tray top with scored cardboard side walls. This setup protects the product during transit but can be easily removed without needing overhead clearance.

5. They’re Versatile and Space-Savvy

Cardboard trays aren’t just easier to handle, they’re highly adaptable to different packing configurations.

For example, when two interlocking trays are used together, you get flexibility in internal height. Let’s say each tray is 4” deep: stacked, they can hold items up to 7.5” tall with a ½” overlap. That means more room to pack varying sizes without having to redesign the whole box.

They also help with securing parts to pallets. Trays can be affixed to a pallet base, and even if the parts are taller than the tray walls, they can still be safely held in place. A second tray can then be placed on top, locking everything down, often eliminating the need for stretchwrap and simplifying your palletizing process.

6. They’re Customizable for Specialty Products

At SmartShield, we design custom cardboard trays to suit the exact size, shape, and weight of your product.

Whether you’re shipping delicate electronics, robotics, or irregular-shaped parts, trays offer a tailored solution that performs just as well as more complex materials, without the complexity.

7. They Support Your Sustainability Goals

With growing pressure to reduce plastic waste and adapt to new regulations - for example, upcoming polystyrene bans - cardboard trays are quickly becoming a go-to alternative.

They’re renewable, recyclable, and designed to maintain the protection and performance your products need, while supporting sustainability goals and closed-loop packaging strategies.

Here’s why more companies are making the switch:

  • Made from renewable, recyclable materials
  • A practical alternative to polystyrene
  • Compatible with closed-loop recycling systems
  • Easily customizable for product protection and branding
  • Cost-effective for both short and long production runs
SmartShield’s Take

We’re seeing more and more clients swap plastic and foam packaging for cardboard tray systems, especially in industries facing tighter material restrictions.

Looking for a real-world example? Here’s how we helped a Canadian robotics company make the switch:

Case Study Spotlight: SmartShield + Avidbots

We partnered with Avidbots to develop protective packaging for their fully autonomous floor-cleaning robots: Kas and Neo.

For Neo, we used a custom pallet and tray system with corrugated pads and a tray-style lid to secure the robot and its accessories. The result: safe, streamlined shipping and easy unpacking at the destination—no loose parts, no confusion.

Why Custom Cardboard Packaging Matters

Looking for a packaging solution that’s both engineered to fit and easy to recycle? Custom cardboard packaging offers a practical, planet-friendly option—especially for businesses aiming to reduce plastic use and improve logistics efficiency.

At SmartShield, we tailor every tray and insert to your product's dimensions, shipping method, and handling needs. That means protection that’s:

  • Lightweight but durable
  • Recyclable and low-waste
  • Built to support 2025 sustainability goals

Cardboard trays are doing more than just holding products—they’re leading the shift to smarter, cleaner packaging strategies.

Want help designing a custom cardboard packaging solution?