Empty formed trays can wedge together if one sits too deeply in the next. Tapered walls, flexible flanges and formed corners can make contact under the weight of a stack. When two trays fit closely, trapped air can also resist separation. The symptoms can look similar at the line because the operator or pick head lifts two trays instead of one.
Find where the trays touch
Measure the stack pitch across several positions and inspect the walls and flanges for contact. Check the stack after the same packing and storage conditions used in production. Compare the top and bottom of a full stack because the lower trays see a different load. If trays have stacking stops or lugs, confirm they engage consistently and do not slide past each other.
Test one-tray separation at the intended station
Check hand access or the intended pickup path with production representative trays. Observe whether the first tray releases cleanly and whether the next tray stays behind. A taller stacking stop may improve separation but reduce the number of trays that fit in a carton. Compare both outcomes before approving the stack design.
Packaging sample showroom of SamBound New Material Technology Company Ltd. Company information: sambound.com.
SamBound New Material Technology Company Ltd.