Blank assembly for forming a reinforced, stackable tray container

A reinforced tray container comprising:

• a pair of opposing side walls each comprising a side panel, reinforcing side panel, and a side pad panel assembly connected to the side panel and the reinforcing side panel, wherein the side panel assembly is configured to be separated from the side panel and the reinforcing side panel for removal from a respective side wall;
• a pair of opposing end walls each comprising an end panel and an end pad panel connected to the end panel, wherein the pad panel is configured to be separated from the end panel for removal from a respective end wall;
• and
• a bottom wall connected to the pair of side walls and the pair of end walls, the bottom wall configured to fold into a cavity of the container to transition the container from an erect configuration to a knocked-down flat configuration.

A method for forming a reinforced tray container from a blank assembly, the blank assembly including a tray blank having a first end panel assembly, a first side panel assembly, a second end panel assembly, and a second side panel assembly in series, wherein each panel assembly comprises a removable pad panel, the tray blank further includes a first bottom end panel assembly extending from the first end panel assembly, a first bottom side panel extending from the first side panel assembly, a second bottom end panel extending from the second end panel assembly, and a second side panel assembly extending from the second side panel assembly, the blank assembly further includes a first side insert blank having a removable pad panel, and a second side insert blank having a removable pad panel, the method comprising:

• coupling the first side insert blank to the first side panel assembly such that the pad panel of the first side insert blank is substantially aligned with the removable pad panel of the first side panel assembly;
• coupling the second side insert blank to the second side panel assembly such that the pad panel of the second side insert blank is substantially aligned with the removable pad panel of the second side panel assembly;
• coupling a coupling panel of the first bottom end panel assembly to the second bottom end panel;
• and
• coupling a coupling panel of the second bottom side panel assembly to the second bottom end panel, wherein the first bottom end panel assembly, the first bottom side panel, the second bottom end panel, and the second side panel assembly are positioned between the panel assemblies.