Custom Four Corner Display Lids With Pop-Up Headers

Sizing the Tray, Lid and Header

Start with how many units go in each display and how they are arranged: lying flat, standing on end, or in angled rows. Measure a single unit and multiply out, adding a small clearance so products can be lifted out easily. A tray that is too tight frustrates shoppers; one that is too loose looks half empty after a few sales.

The header height is set by the lid depth. A deeper lid gives a taller header, which is more visible but adds board and height to the shipping case. On a busy counter, a header that rises just above the product line is usually enough to catch the eye without blocking the till. If the display will sit on a shelf rather than a counter, check the shelf height so the header fits beneath the shelf above. Our guide on how to measure one unit for the tray explains how much room each cell needs.

Board Strength and Shipping

Most four corner displays are made from E-flute or B-flute corrugated board. E-flute is thinner, prints beautifully and suits light products. B-flute is thicker and stronger, used for heavier products or displays that travel through distribution networks stacked on pallets. Folding board versions exist for very light items, but corrugated is more reliable through the post and the warehouse.

If displays will be stacked several high during shipping, the corners and tray walls take the load. Locked corners add strength, and the closed lid spreads weight across the top. We can suggest a board based on product weight and how the displays will be shipped, whether in an outer carton or on their own. You can see E-flute and B-flute compared in our board guide.

Printing Header, Tray and Lid

The header is the star, so plan its artwork first. Keep it bold and simple: brand name, product name, maybe one short line or a price point if your retailers want it. Shoppers glance for a second at most, so a big logo and a strong image beat paragraphs of text. Remember the header is seen from the front when folded back, so the artwork sits on what is the inside of the lid during shipping.

The tray front and sides are also visible, and printing your brand around them reinforces the header. The outside of the lid, seen only during shipping, can carry handling information, a product code and a barcode for the wholesale case. Full colour print works well for confectionery; one or two spot colours are cost-effective for simpler ranges. The free proof shows exactly how each panel reads in both shipping and display positions.

Getting Displays Into Shops

Retailers have limited counter space and plenty of brands competing for it. A display that is easy to set up, takes little room and looks tidy until the last unit has a better chance of staying out. A clean, well-printed four corner display that opens in seconds is a stronger argument when a sales rep or wholesaler is persuading a shop to take a product.

Some brands print a reorder message or web address on the base of the tray, visible once the display is nearly empty. It is a small touch that can prompt a shop to restock before the product disappears from the counter.

Think about the moment a shop receives the case. A clear instruction printed on the lid, such as a simple fold-back arrow and a few words, means a busy assistant sets the display up correctly the first time rather than tearing the lid off and losing the header. Brands that skip this step often find their displays on counters with no header at all, which wastes the most valuable part of the print. Stockists supplied by courier usually receive product display boxes for stockists in an outer case.

Decide Whether the Display Ships Filled, Then Size the Header

The first decision for a four corner display lid is whether it travels full or empty, because a filled display is a shipping case first and a display second. If it ships full, send the packed weight so the board resists stacking, and plan the lid print for the inside, since that face becomes the header. Then size the tray to the number of units a shop will sell between visits and measure one unit at its widest and tallest point. The header should rise above the products without blocking the till, and many brands print a short set-up line on the outer lid so staff fold it correctly. A matching counter display for single units can sit beside it at the till.

Send the product size, units per display, weight and artwork, and a custom quote comes by email within one working day. The free proof shows the tray, lid and header with artwork in position. Production takes 4 to 7 working days after approval, displays arrive flat or formed by tracked courier to UK mainland addresses, and misprinted or damaged displays reported within 10 days are reprinted or refunded.