This boxer underwear PDQ tray is a heavy duty shelf-ready cardboard tray developed for club store and warehouse format retail, where multi-pack apparel is merchandised straight from the pallet or shelf without unpacking. The tray measures 60.4 x 50.1 x 40 cm and is built from double wall EB flute with a 350gsm CCNB liner on the main body, reinforced with EE double wall board in the load bearing areas, so a fully packed tray carries up to 20 kg of boxed underwear without bulging, sagging or losing its rectangular shape. That load rating is the difference between a tray that survives a club store floor and one that collapses halfway through a promotion.

Printing is five colour offset with a matte lamination, which reproduces brand colour, size identification blocks and product photography sharply while avoiding the glare that glossy film produces under high bay warehouse lighting. The matte finish also hides scuffs from forklift handling and repeated restocking. The tray is delivered flat packed in bulk to a factory in China, where our team assembles it, fills it with your boxer packs and ships it floor ready, so the store receives a finished unit instead of flat board and a labour task. That fulfilment step is the single biggest cost saver in the programme, because assembling and filling trays in store consumes staff hours that club store buyers now refuse to fund.

• 20 kg load capacity: double wall EB flute body with EE double wall reinforcement in the base and corners carries a full pack of boxed underwear without deformation, tested to club store loading conditions.
• Club store footprint: 60.4 x 50.1 cm base matches standard pallet and shelf modules, and the 40 cm wall height keeps multi-packs visible while holding enough units to justify a promotional facing.
• Five colour offset printing: 5C process gives one extra colour beyond CMYK for brand accent or size coding, keeping product families distinguishable at a glance on a crowded apparel aisle.
• Matte lamination: a non glare matte film keeps print readable under warehouse high bay lighting, resists scuffing from forklifts and trolleys, and holds colour through a full promotional cycle.
• Shelf-ready construction: the tray presents product directly on shelf or pallet base, with clean front and side panels for brand messaging and no separate display fixture required.
• Bulk flat pack: trays ship as flat blanks in bulk, cutting freight volume and warehouse space compared with assembled units, and stack efficiently in a back room.
• China factory fulfilment: we receive your product, assemble the tray, fill and protect the packs, then ship a floor ready unit, removing assembly and merchandising labour from the store.
• Eco conscious materials: paper based board and liner with soy based plant ink free of mineral oil, meeting European environmental requirements and suitable for standard paper recycling.

The tray is built for apparel and accessories sold in multi-packs: boxer shorts, briefs, socks, t-shirts, undershirts, pyjama sets and activewear, particularly where a retailer sells value packs of three, five or seven units. Beyond apparel, the same structure suits other club store categories that need a 20 kg rated shelf-ready tray, such as packaged towels, bedding sets, household consumables and multi-pack personal care. The format is designed around the practical realities of warehouse retail: strong enough to sit on a pallet base, shallow enough for a shopper to reach into, and printed clearly enough that a member can identify size, colour and pack count without unfolding a box.

Because the tray is shelf-ready, it also removes a step from the retail supply chain. In a conventional programme the store receives cartons, opens them, builds the display, fills the display and then breaks down the cartons for recycling. In this programme the tray arrives already assembled and filled, the store simply removes the outer shipping carton and places the unit on the floor. Fewer handling steps means less damage to product, faster promotional set up and measurable labour savings per store, which is exactly the metric club store buyers negotiate on.

We operate a China factory fulfilment service for this type of tray. Your product is delivered to our facility, where the trays are assembled, filled with the packed boxer sets, protected with tissue or divider sheets where needed, closed and packed into a shipping carton labelled for store delivery. Each unit is checked for squareness, fill completeness and print condition before it is sealed. Retailers who have run this model report that store labour drops sharply, because the only remaining task is to place the unit on the selling floor. We can also hold buffer stock at the factory so that repeat store orders ship without a new production lead time.

Trays are flat packed in bulk for the initial shipment to our factory, then assembled and shipped floor ready. Each production run is inspected for board thickness, burst strength, print registration, lamination adhesion, glue and lock integrity and dimensional accuracy against the approved die line. A white sample is produced first to confirm structure and load bearing, followed by a printed colour sample for sign off before mass production. Standard bulk delivery is about twelve to fifteen days after artwork approval, with samples in two to five days.