Shipping fragile products can feel risky, especially when over 12% of parcels arrive damaged. Good news, you can cut your breakage rate by up to 25% with tailored cardboard packaging inserts, according to insights from Smurfit Kappa’s Experience Centres. These recyclable dividers slot neatly into your boxes, separating delicate items and absorbing shocks, all while supporting your sustainability goals.
In this guide, you’ll learn how cardboard inserts work, why they excel with fragile goods, and how to choose the right design for your needs.
Choose cardboard dividers
Cardboard packaging inserts, sometimes called cardboard box dividers, are flat, die-cut sheets that slot together to form partitions within a carton (or tray). They:
- Keep items separated, preventing contact damage.
- Absorb shocks at each contact point.
- Fit around odd shapes for a snug hold.
By using partitions that match your product dimensions, you avoid unwanted movement and ensure each fragile item has its own protective cell.
Boost protection for fragile items
When you ship glassware, perfume bottles or mechanical parts, even small knocks can cause cracks or scratches. Cardboard dividers help by:
- Creating individual cells, so items can’t collide.
- Distributing impact forces evenly across the structure.
- Reducing vibration during transit (a common cause of micro-fractures).
Types of cardboard dividers:
- Partitioned trays: simple grids for bottles or jars.
- Column pads: wraparound separators for grouped items.
- Shelf separators: multi-tier design for stacked products.
- Die-cut shapes: custom contours for unique geometries.
Design your cardboard inserts
A good fit starts with accurate measurements. Follow these steps:
- Measure your products (height, width, depth) and include any protective film or wrapping.
- Define cell size and wall thickness based on item weight (thicker walls for heavier loads).
- Use a tool like DESIGN2MARKET to upload your SKU dimensions, visualise fit and tweak spacing with minimal risk.
- Visit an Experience Centre (Smurfit Kappa offers these at key locations) to handle prototypes, test assembly speed and see real-world performance.
Prototyping in person helps you spot pinch points or clearance issues before full production.
Improve sustainability and savings
Corrugated cardboard has clear eco-benefits, and swapping out foam or plastic can boost your green credentials:
| Feature | Cardboard inserts | Foam inserts |
|---|---|---|
| Recyclability | High (100%) | Low |
| Material cost | Moderate | High |
| Customisation speed | Fast | Moderate |
| Storage space required | Flat-pack friendly | Bulky |
Additional savings:
- Lower disposal fees since cardboard enters standard recycling streams.
- Reduced storage costs (flat sheets stack neatly).
- Potential bulk-buy discounts for standard divider sizes.
Good news, these savings often offset design and tooling fees within the first few orders.
Work with a packaging partner
You don’t have to navigate inserts alone. A specialist provider can help you:
- Develop bespoke designs that match your brand and product range.
- Access modelling tools and prototyping services (for example DESIGN2MARKET).
- Tap into hands-on testing at Experience Centres (no guesswork, just real samples).
- Benefit from end-to-end support, from initial concept through to mass production.
Partnering early in your packaging process speeds up time to market and cuts costly revisions.
Recap and next steps
- Choose the right divider style for your product.
- Measure accurately and plan cell dimensions.
- Prototype using digital tools and in-person testing.
- Compare cardboard with alternative materials for savings.
- Collaborate with a packaging partner for expert support.
You’ve got this, and by adding cardboard dividers you’ll protect fragile goods, lower costs and hit your sustainability targets.
Frequently asked questions
1. What are cardboard packaging inserts used for?
They form partitions inside cartons to separate and protect individual items, ideal for glass, perfume bottles and precision parts.
2. Are cardboard inserts recyclable?
Yes, corrugated cardboard inserts are fully recyclable through standard paper recycling streams, making them a sustainable choice.
3. How do I choose the right thickness?
Select wall thickness based on item weight and fragility—light products often work with single-wall board, whereas heavier loads need double-wall or reinforced sections.
4. Can I test designs before full production?
Absolutely. Tools like DESIGN2MARKET let you visualise fit digitally, and Smurfit Kappa’s Experience Centres offer hands-on prototype testing.
5. Do inserts add much to shipping costs?
Inserts can actually lower overall costs by reducing damage-related returns and waste, plus they often require less storage space than loose fill or foam alternatives.