Packaging Inserts: The Unsung Heroes of Protection

There are many items in our lives that we use on a regular basis but don’t give a lot of thought to. Seatbelts, doormats, and even circuit interrupters are there to make us safer, but we don’t spend a lot of time assessing their beauty, design atheistic, or notice the differences between one design and another. The same thing applies to the inserts that are used in packaging. You probably don’t really think about them, but you need them, and you have some choice as to which one to use.  We are going to get you more familiar with some of them right now.

There are two main functions for using inserts in your packaging plan.

  1. Protection – preventing damage in shipment
  2. Presentation – delivering the best possible unboxing experience for the consumer


We have created inserts, partitions and dividers in many different forms and shapes and functions – all in die cut corrugated designs.

Here are the top 5 reasons that die cut corrugated designs are the most popular option you may have:

  1. Flexibility and Versatility – if the product or quantity changes, it can easily be modified or replaced
  2. Affordability
  3. Less messy for the end user – no one ACTUALLY loves peanuts and shredded paper – don’t kid yourself
  4. Printable – this is another great opportunity to use the packaging to brand and message to the end user
  5. GREENER – they can be made of 100% recycled board, so if this matters to you or your end user, it is a great story to tell

From a design perspective, they provide endless options and possibilities in structure and shape. Here are three different designs for the same four pack of deodorant sticks.

  1. Scored sheet divider – this is a low cost, effective design that does not require a cutting die investment. Mailing and storage costs are also minimized because in this case the product does not require a protective perimeter air cell, for a very tight, clean, simple and economical design.
  2. Die cut cavities – in situations where space around the product is desired the insert can be cut with as many openings or cavities as necessary. Most custom cutting dies require a $300 to $600 onetime investment but save hours of valuable packing time if designed properly.
  3. Elevated and angled die cut design – For a unique presentation that really shows off the product, many products can be placed in an insert at an angle or eye-catching configuration. Reproducing the instore, retail experience when shipping direct to the consumer is not always easy but a creative design can help you create that Instagram worthy look.

Inserts are kind of the unsung heroes of your packaging plan, and we hope we have shed some light on the different kinds that are available to you.

Reach out today to learn more, see some samples, or have one of our packaging engineers help you figure out which solution is right for you.


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