Cardboard packaging separators play a crucial role in safeguarding your bottles, jars and delicate products during transit. As a logistics or quality manager for a winery or craft brewery, you know that breakage not only dents your reputation but drives up returns and after-sales costs. In this guide you’ll discover how to choose the best cardboard packaging separators to reduce damage, optimise cost and support sustainable packaging practices.
Understand your needs
Before you evaluate designs or materials, define your specific requirements. A clear brief helps you compare options more effectively.
Identify breakage risks
List the main causes of damage in your supply chain. For example:
- Vibration and shocks during loading and unloading
- Lateral movement inside boxes
- Stacking pressure from pallets
Knowing which risk is most common informs the choice of separator style and flute profile.
Consider product dimensions
Measure your bottles or containers accurately:
- Height, width and depth of each unit
- Neck or cap protrusions
- Weight per item
These dimensions guide the thickness and strength of separators you need, and ensure a snug fit that prevents shifting.
Review shipping conditions
Think about how your packages travel:
- Multi-temperature environments for wine or beer
- Long-haul lorries versus local couriers
- Hand-led fulfilment in urban centres
Different routes and handling methods can change how much cushioning or rigidity you require from your separators.
Explore separator types
There are several common forms of cardboard packaging separators. Each serves a unique purpose.
Cross-shaped separators
Also known as “croisillons en carton”, these X-shaped inserts divide the box into four or more cells. They excel at:
- Separating individual bottles without side contact
- Offering vertical compression resistance
The Estic-Maillot Packaging Group has refined this design since 1924, supplying bespoke croisillons that meet European wine-industry standards (Estic-Maillot Packaging Group).
Tray dividers and sleeves
Cardboard tray dividers sit flat under bottles, adding a layer between box base and products. Sleeves wrap around bundles, securing items laterally. Key benefits include:
- Easy insertion and removal
- Compatibility with packaging box inserts for added cushioning
Sheet dividers
Flat sheet dividers stack between layers of products. They’re ideal when you need horizontal separation, for instance:
- Bottles laid on their sides
- Jars or cans stacked in multiple rows
Evaluate material options
Choosing the right substrate affects both protection and sustainability.
Corrugated board grades
Corrugated board comes in single wall (three papers) or double wall (five papers) structures. Single wall suits light loads or short distances. Double wall adds rigidity for heavier bottles or longer hauls.
Single vs double wall
| Feature | Single wall | Double wall |
|---|---|---|
| Paper layers | 3 | 5 |
| Flute thickness | ~3–4 mm | ~6–7 mm |
| Vertical compression | Moderate | High |
| Typical use | Local dispatch | Long-distance |
Sustainable fibres
Corrugated board often uses recycled fibres and is fully recyclable. Ask your supplier about:
- Percent recycled content
- Certifications (e.g. FSC or PEFC)
- Biodegradability
Assess design features
Effective separators balance strength, fit and cost.
Flute profiles and strength
Different flute profiles (E, F, B for single wall; EB, EC for double wall) affect cushioning and compression:
- E flute: thin, good for printing and light items
- B flute: standard, balances strength and cushioning
- EB flute: double-flute for heavy loads
Refer to the detailed flute guide in this table:
| Flute profile | Thickness | Best for |
|---|---|---|
| E | 1.6 mm | Fine printing, light items |
| F | 0.8 mm | Compact products, high detail |
| B | 3.2 mm | General use, moderate protection |
| EB | 6.0 mm | Heavy bottles, multi-layer loads |
Customisation and printing
Digital printing technologies let you add logos, handling instructions or batch codes without expensive tooling. Sietcam’s 8-colour digital inkjet printer uses water-based inks, reducing waste and setup time (Estic Maillot).
Interlocking vs glued designs
- Interlocking tabs speed assembly and disassembly, ideal for high-volume runs
- Glued joints offer seamless strength, preferred for automatic packing lines
Examine manufacturing quality
Supplier capabilities directly influence separator performance and lead times.
Production technologies
Look for advanced equipment such as:
- Dual-beam plotting tables that cut two sheets simultaneously
- Numerically controlled hotmelt plotters for uniform gluing
These investments double throughput and reduce human error, ensuring consistent quality.
Digital printing advantages
Hybrid printing methods combine offset for standard elements with digital for customised sections. This lets you:
- Optimise costs for common graphics
- Deliver unique branding on each batch
Quality control measures
Ask about your supplier’s QC protocols:
- Batch testing for compression strength
- Dimensional checks on every 100 units
- Moisture and burst resistance assessments
Optimise for sustainability
Your eco-credentials matter to customers and regulators.
Recycled and recyclable materials
Confirm that both liner and fluting papers are recyclable. Some suppliers guarantee 100 percent recycled content, lowering your carbon footprint.
Low-waste production
Digital cutting and printing minimise make-ready waste. Sietcam’s process reduces paper spoilage compared to die-cutting methods, making each sheet count (Estic Maillot).
Eco-friendly inks
Water-based or soy-based inks offer lower VOC emissions and easier recycling, while still delivering sharp colours and clear text.
Calculate cost effectiveness
Budgeting for separators often involves more than just unit price.
Tooling and setup costs
Traditional flexo or offset printing may incur plate charges. Digital methods typically eliminate these, making low-volume or customised orders more economical up front.
Volume discounts
Many suppliers tier pricing by order size. Map out your annual usage, then negotiate brackets that align with your forecast.
Return on investment
Factor in savings from reduced breakage:
- Lower return rates
- Fewer customer complaints
- Decreased insurance claims
A small premium on premium separators can deliver significant overall programme savings.
Implement best practices
Even the best separators underperform without proper integration.
Partner with reliable suppliers
Choose vendors with relevant expertise in wine or beverage segmentation. The Estic-Maillot Group, for example, operates eight plants across Europe and North America, offering nearly 100 years of know-how (Estic-Maillot Packaging Group).
Test prototypes
Before a full rollout:
- Order short runs of each candidate design
- Conduct drop and vibration tests
- Fit actual products in Europe-to-US or intra-Europe routes
Integrate with box inserts
Pair separators with packaging box inserts or foam pads for extra shock absorption, especially for fragile vintage bottles or limited-edition craft brews.
Frequently asked questions
What are cardboard packaging separators?
Cardboard packaging separators are internal dividers made from corrugated board that keep individual items apart, minimising contact and absorbing shocks during transit.
How do I choose the right flute profile?
Match flute thickness to your product weight and handling needs. Lighter items may work with E or F flutes, while heavier bottles benefit from B or double-flute (EB, EC) structures.
Can separators be reused?
Yes, in many cases you can reuse separators several times if they remain intact and dry. Implement a inspection process to check for creases or moisture damage before reuse.
Are digital prints durable?
Modern water-based and UV inks bond strongly to corrugated facings. They withstand scuffs and humidity in typical warehouse environments, while also speeding up production lead times.
How much do separators cost?
Prices vary based on material grade, flute profile, printing and order volume. Expect single wall separators to start around €0.10–€0.30 per unit in bulk, with double wall or highly customised versions ranging higher. Always request detailed quotes to compare all cost factors.
With the right cardboard packaging separators in place, you’ll protect your products, bolster customer satisfaction and keep logistics costs under control. Start by defining your needs, testing prototypes and partnering with an experienced supplier. Your next shipment can be both secure and sustainable.