In a competitive retail landscape, presentation is as important as the product itself. Every component of a store layout—from shelving to signage—plays a role in influencing buying decisions. One often overlooked but critical component is the humble retail tray. These functional units not only house products but help maximise space, boost visibility, and contribute to operational efficiency. Optimising tray design is an essential aspect of modern retail strategy.
The Role of Trays in Retail Strategy
Retail trays serve multiple purposes:
- Product organisation and containment
- Brand presentation and display enhancement
- Ease of handling, stocking and replenishment
- Shelf-ready packaging (SRP) for rapid store setup
- Reducing waste and transport costs through reusability and stackability
To truly optimise a retail tray design, retailers and suppliers must consider both material selection and functional design.
The Optimum Material for Retail Trays
Material choice significantly affects the tray’s performance, cost, and environmental footprint.
- Corrugated cardboard is cost-effective and recyclable, but only suitable for short-term or single-use display. It is prone to damage and deterioration when exposed to moisture or heavy use.
- PET (polyethylene terephthalate) plastic containers are suitable for food goods and high-end electronics, but they can be costly and less sustainable if not reused or recycled properly.
- Wood or MDF offers a premium, rustic aesthetic, but it’s more cumbersome and less easy and efficient to handle. Without treatment, it’s also prone to moisture damage.
- Corrugated polypropylene (PP) is ideally suited to the demands of busy retail environments. It’s lightweight yet strong and robust enough to hold heavy items. It’s also highly durable, waterproof and chemical-resistant, making it ideal for chilled, frozen, or chemically sensitive environments. PP is reusable and 100% recyclable, aligning with closed-loop and circular economy objectives.
Purpose-Driven Structural Design
A retail tray should be designed around both the product’s physical characteristics and the retail environment’s constraints.
Research published in Packaging Technology and Science (2021) found that ergonomic display trays designed with visibility and accessibility in mind increased customer dwell time and sales by up to 12% in impulse-buy zones. Retailers can collaborate with bespoke tray manufacturers to determine and develop the optimal solution.
Key structural features to consider include:
- Stackability: Ensures stability during transport and allows vertical merchandising.
- Custom compartments or inserts: Useful for displaying multiple SKUs neatly.
- Front cut-outs or angled walls: Improve visibility and customer accessibility.
- Integrated handles: Simplify movement for staff during replenishment or restocking.
- Flat-pack options: Improve storage and shipping efficiency before assembly.
As a manufacturer of bespoke corrugated polypropylene products, Twinplast utilise the material’s inherent design versatility to incorporate these features into custom display solutions on behalf of retail clients.
The Value of Customisation and Branding
Retail trays aren’t just about function—they’re also a canvas for brand storytelling.
Custom-printed trays or coloured plastics aligned with brand identity can enhance the customer experience and make your products stand out on crowded shelves.
For example:
- Using on-brand colours can reinforce recognition
- Including logos or QR codes can direct customers to digital promotions
- High-quality tray finishes can convey product quality
Twinplast’s in-house printing facilities provide clear and eye-catching visuals for display solutions, increasing the impact and effectiveness in retail environments.
Modular Functionality
Modular functionality can be pivotal in retail display.
A 2020 study published in the Journal of Retail & Consumer Services found that using adaptable modular display systems can increase shelf efficiency by 15–20%. These systems also help accelerate the implementation of planograms, enabling retailers to optimise product placement and respond more swiftly to market changes.
Adaptable modular trays are designed for flexibility. Detachable and adjustable dividers can be easily reconfigured to fit different product dimensions and categories.
This adaptability allows retailers to quickly adjust displays, reduce downtime during promotional changeovers or seasonal resets, and to launch promotions more rapidly—staying agile in competitive markets.
Modular display systems significantly improve shelf efficiency by maximising the use of available space—allowing for more products to be stored and displayed within the same footprint. Their standardised, efficient layouts improve inventory management by allowing for more accurate stock control, easier restocking, and reduced labour time and costs associated with resetting shelves or implementing new layouts.
They can also improve product visibility and accessibility, which can directly impact customer purchasing decisions and increase conversion rates.
Designing for Performance and Sustainability
Tray design in retail should never be an afterthought—it’s a strategic tool.
By selecting the right materials and optimising structure for real-world use, retailers can reduce operational inefficiencies, boost product appeal, and support sustainable practices.
Twinplast’s corrugated polypropylene trays provide a compelling balance of strength, sustainability, and customisability, making them a smart choice for forward-thinking retail operations.
To find out more, get in touch with our team today on 01582 361720 or
sales@twinplast.co.uk.