Carton separators give your shipments structure and protection, dividing boxes into individual cells so fragile bottles and containers stay in place. By using the right carton separators you can dramatically cut damage in transit, reduce returns and lower your after-sales costs. In this article you’ll learn how to choose, design and test separators that fit your wine or craft-brew operation, all while keeping sustainability and budget in mind.
Understand carton separators
What are carton separators
Carton separators are internal dividers—often made from corrugated or honeycomb cardboard, foam sheet or fibreboard—that slot into your outer box. They create compartments for individual items, preventing lateral movement and cushioning impacts. In French packaging terminology you’ll see them referred to as croisillons en carton (Estic-Maillot), but whichever label you use, the goal is the same: keep each bottle or can in its cell to avoid contact and breakage.
Why use carton separators
If you ship bottles of wine, craft beer or spirits, you know that one shattered bottle can skew your cost calculations. Carton separators:
- Cut lateral shocks when boxes are jostled or stacked
- Spread load evenly to prevent pressure points
- Simplify packing by defining fixed slots
- Work with other inserts to add extra cushioning
With your average return or replacement costing significantly more than the price of a separator, investing in quality dividers quickly pays back.
Evaluate separator materials
Choosing the right material comes down to weight, fragility and sustainability. Here’s a quick comparison:
| Material | Key features | Best for |
|---|---|---|
| Corrugated cardboard | Cost-effective, recyclable | Light to medium-weight bottles |
| Honeycomb cardboard | High strength, excellent cushioning | Fragile or heavy glass containers |
| Foam sheet separators | Superior shock absorption | Delicate glassware, electronics |
Corrugated cardboard dividers
These are the most common separators. You can source them off-the-shelf or customise cell sizes to match your pack count. Corrugated dividers are cost-effective and fully recyclable, making them popular for operations seeking a balance between price and performance.
Honeycomb cardboard separators
Honeycomb cardboard offers higher compressive strength. Its unique structure disperses impact across a wider area, ideal when you pack heavier bottles or multiple units per box. Although slightly pricier, honeycomb dividers deliver peace of mind for premium content.
Foam sheet separators
If you handle ultra-fragile bottles, foam sheet separators provide extra shock absorption. They’re easy to trim to non-standard shapes, but you’ll want to confirm compatibility with your sustainability goals, as not all foam types are recyclable.
Consider structural design
Cell size and thickness
Your product dimensions dictate cell measurements. Too tight and you risk container stress; too loose and items can tumble. Aim for a snug fit that leaves room for a thin protective layer around each unit.
Custom shapes and interlocking
Many suppliers offer die-cut separators that fold into interlocking grids, speeding up assembly. If you have unique bottle shapes—such as rectangular liquor bottles or wax-sealed wine bottles—ask for bespoke tooling. Custom profiles ensure a perfect fit and optimal protection.
Integrate separators into packaging
Pairing with boxes
Separators work best inside a robust outer box. Choose a box grade that matches your separator’s capacity. For instance, a double-wall corrugated box pairs well with honeycomb dividers when stacking multiple cases on a pallet.
Using packaging box inserts
To further enhance cushioning, combine your separators with soft inserts or pads. For guidance on complementary inserts, see our article on packaging box inserts. Strategic layering—foam pad, separator grid, then another foam pad—can absorb double the shock.
Assembly and loading tips
- Pre-assemble separator grids and set them aside in the packing area
- Train staff to place bottles upright and central in each cell
- Seal the box firmly, avoiding over-torquing tape which can compress dividers
A consistent packing routine helps you maintain protection standards across every shipment.
Review cost and sustainability
Cost per unit and return on investment
Calculate the per-unit price of each separator against your average cost of a return or replacement. Even if a divider adds a few cents to your packing bill, reducing just one breakage per pallet can cover that expense many times over.
Eco friendly benefits
Most cardboard and honeycomb materials are made from recycled fibres and are fully recyclable after use. By opting for green materials you lower your carbon footprint and appeal to environmentally conscious customers.
Case study: Estic-Maillot Packaging Group
Estic-Maillot Packaging Group, a French family business founded in 1924, has specialised in fibreboard partitions—croisillons en carton—for a century. Since 1999 the group has grown to eight production sites across France, Europe and the United States, ensuring fast delivery throughout Europe and the US Southeast (Estic-Maillot). Their cost-effective, eco-friendly separators are designed to reduce product breakage, making them a go-to partner for wine houses and craft breweries looking to cut return costs.
Test and monitor performance
Prototyping and damage testing
Before you roll out a new separator design, pack a sample batch and run basic drop and vibration tests. Record any shifts in breakage rates so you can compare against your current packaging setup.
Tracking return rates and adjustments
Set up a simple log for returned cases—note separator type, box grade and damage location. Over time you’ll spot patterns that guide you to tweak cell size, material or assembly method. Continuous monitoring ensures ongoing cost savings.
Frequently asked questions
How do I choose the right separator material?
Assess your product weight and fragility first. Corrugated cardboard fits most standard bottles, while honeycomb panels work best for heavier or more delicate items. Foam sheet separators offer extra shock absorption but check recycling options before you buy.
Can separators handle different bottle sizes?
Yes. Many suppliers provide die-cut or laser-cut separators that suit any bottle diameter or height. Custom tooling may carry an additional setup fee, but it pays off by delivering a perfect fit and maximising protection.
Are carton separators recyclable?
Most carton separators—especially corrugated and honeycomb cardboard—are fully recyclable. Confirm with your supplier that no non-recyclable coatings or laminates are used if sustainability is a priority.
How do separators reduce return costs?
By creating fixed compartments, separators prevent items from colliding inside the box. This minimises breakage during handling, transit and stacking. Fewer damaged units mean fewer returns and lower after-sales expenses.
Where can I find custom separator solutions?
Start with specialist manufacturers like Estic-Maillot Packaging Group, who offer custom die-cut and interlocking options across Europe and the US (Estic-Maillot). You can also work with local converters who provide on-demand prototyping and small-batch runs.