Custom Packaging Inserts

Yes, you can. Many of our clients use a Die-Cut Insert for base protection and add a Brand Story Card or Thank You Note on top. We can match the paper weights so everything feels consistent.

People often use these terms to mean the same thing, but a Fence Partition usually means interlocking strips for bigger, flatter items. Cell Dividers are made for deeper, three-dimensional objects like jars or canisters.

We offer both options. You can get instruction sheets as flat inserts, or choose multi-page leaflets and user manuals that are pre-folded to fit into even the smallest slots in your box.

Start by measuring the inside of your box, not the outside flaps. Choose dividers that are 1/4 inch shorter than the box height so the lid closes easily. The width and length should be 1/8 inch smaller than the inside of the box for a good fit. If you are unsure between two sizes, pick the smaller one. A slightly loose divider is better than one that is too tight.

Yes, we offer recycled paperboard in different thicknesses. For heavier items, we suggest using a multi-ply scored pad or a heavy-duty Kraft divider. These options are strong and do not use virgin plastics.

Yes, but the material you choose is important. Corrugated dividers can handle moisture from ice pack condensation for 24 to 48 hours without losing strength. For shipments that last more than 72 hours, it’s best to use coated corrugated or foam dividers. Foam inserts are not affected by moisture. One of our clients has shipped over 10,000 cold packs with corrugated dividers and has not seen any failures during two-day transit.

Most modern cartoning machines use two ways to handle dividers. One is manual pre-insertion, where an operator puts the divider in the box before it enters the machine. The other is mechanical insertion, where the divider feeds from a magazine. For mechanical feeding, dividers must have consistent dimensions within a ±1/16 inch tolerance. Interlocking grid dividers usually need to be assembled by hand, but single-piece foam inserts can be used with full automation. Please share your machine specifications with us during the design process, and we will confirm if everything is compatible.

Pre-fitted boxes, where inserts are glued in during production, are more expensive. Buying boxes and inserts separately is cheaper at the same volume. Pre-fitted boxes save on labor since there is no assembly needed, but you lose the flexibility to switch box suppliers or change configurations between production runs.

Try using stepped dividers, which have different cell heights in the same insert, or use layered inserts. For example, if you have a skincare set with tall pump bottles and short jars, you can use a divider with 6-inch cells for bottles and 3-inch cells for jars, all in one piece. Another option is to use two separate insert layers: place a shallow tray on the bottom for jars and a taller grid on top for bottles. Stepped dividers usually cost the same as regular dividers, while layered inserts add 40-60% to the cost but offer better protection and a more attractive look.

Yes, we can make custom-printed inserts with your own artwork or graphics. These usually cost an extra $0.12 to $0.50 per insert, since we need to set up the printing. If you only need a small number of inserts, colored labels can give a similar branded look for less.