Packaging crossbars slot between individual bottles or containers in a carton, locking them in place to absorb shocks and prevent movement. As a logistics or quality manager at a wine house or craft brewery, you know that even a single broken bottle can dent your reputation and inflate your service costs. By integrating packaging crossbars into your shipping strategy, you can reduce breakages, slash returns and protect your brand.
In this article, you’ll discover what packaging crossbars are, how to assess your transit risks, how to choose the right materials and design, and how to monitor performance to deliver real cost savings. Let’s dive in.
Understand packaging crossbars
What are crossbars
Packaging crossbars are structural separators made from corrugated or honeycomb cardboard that slot horizontally between bottles, jars or fragile goods. They create individual cells or compartments, absorbing impacts and minimising lateral movement. Unlike loose fill or foam peanuts, crossbars offer consistent spacing, reliable cushioning and an eco friendly profile.
Why choose crossbars
You might already use foam, bubble wrap or moulded pulp to cushion your products. Crossbars add value by:
- Providing uniform support under load and during stacking
- Reducing damage from side impacts and vibration
- Streamlining packing operations with fewer components
- Offering a recyclable, lightweight solution
When you combine crossbars with complementary inserts, you create a robust packaging system that guards against the bumps, drops and shifting loads of international transport.
Assess your transit risks
Common breakage scenarios
Before you specify crossbars, map out how your goods travel:
- Road transport on uneven surfaces, where vibration can loosen bottles
- Multi modal transfers, where handling points multiply
- Stacking in warehouses and trailers, adding compressive forces
- Temperature swings, causing cardboard to lose rigidity
Factors affecting product safety
Several variables influence how well crossbars protect your goods:
- Weight distribution – heavier bottles exert more pressure on separators
- Carton dimensions – mismatched sizes reduce cushioning effectiveness
- Humidity and exposure – moisture can weaken corrugated structures
- Handling frequency – more touch points increase the chance of drops
Assess each factor in your supply chain so you can tailor crossbar design and material choice to your specific risks.
Choose the right materials
Cardboard crossbars properties
Corrugated cardboard remains the most common crossbar material thanks to its:
- High strength-to-weight ratio
- Cost effectiveness and scalability
- Recyclability and compostability
Since 1924, the Estic-Maillot Packaging Group has specialised in manufacturing cardboard crossbars, bringing nearly a century of expertise to your supply chain (Estic-Maillot Packaging Group). In 1999, they expanded to eight production sites across France, Europe and the Southeastern United States, ensuring regional support and faster delivery for your projects (Estic-Maillot Packaging Group).
Honeycomb and laminated options
For higher impact resistance or unique branding needs, consider:
- Honeycomb cardboard, which delivers extra rigidity for heavier loads
- Laminated corrugated boards, allowing high-quality printing and moisture resistance
- Multi-layer constructions, combining the best attributes of different substrates
| Material | Strength | Weight | Cost | Sustainability |
|---|---|---|---|---|
| Corrugated cardboard | Medium | Light | Low | High |
| Honeycomb cardboard | High | Medium | Medium | High |
| Laminated corrugated | Variable | Medium | Medium-high | Medium |
Use the table above to match material properties with your product weight, fragility and environmental priorities.
Optimise crossbar design
Custom shapes and dimensions
Off-the-shelf crossbars work for many standard bottles, but you may need bespoke cuts or slots to:
- Fit unique bottle necks or shoulders
- Accommodate handles on growlers or specialty jugs
- Create asymmetric compartments for mixed-item shipments
Work with your supplier to produce die-cut patterns that match your carton interior. Precise dimensions ensure each item sits snugly, cutting movement to zero.
Colour coding and printing
Printed crossbars help you streamline warehouse operations. You can:
- Use distinct colours for different SKUs or vintage years
- Print instructions, batch numbers or branding directly on separators
- Incorporate barcodes or QR codes for automated scanning
By turning crossbars into informative packaging components, you reduce packing errors and speed up order fulfilment.
Combine with packaging box inserts
Synergy of crossbars and inserts
Crossbars excel at lateral support, while inserts absorb vertical shocks. When you combine both, you achieve a complete protective system:
- Inserts cradle the base and shoulders of bottles
- Crossbars lock items in place horizontally
- Together they prevent tilt, slide and top-down impacts
Integrating packaging crossbars with packaging box inserts makes your cartons more resilient to multi-directional forces.
Case example
A mid-sized craft brewery in Burgundy reported a 60% drop in breakages after switching to a combined system:
- Custom corrugated inserts supporting the bottle bottom and neck
- Honeycomb crossbars creating six separate chambers in each carton
- Printed crossbars marking vintage year and batch code
Within three months, returns fell by a third and customer satisfaction scores climbed, validating the upfront design investment.
Implement quality control
Testing and certifications
To guarantee performance, subject your crossbar solutions to standard tests such as:
- Edge crush test (ECT) for stacking strength
- Vibration table trials mimicking road and rail transport
- Compression tests at different humidity levels
Look for suppliers with ISO 9001 or ISTA certifications to ensure consistent quality and traceable manufacturing processes.
Supplier partnerships
Building a close relationship with your crossbar supplier helps you:
- Iterate designs based on real-world feedback
- Secure rapid prototyping when you launch new products
- Lock in volume discounts as your order size grows
Treat your supplier as a strategic partner rather than a commodity source.
Monitor performance and ROI
Tracking breakage rates
Implement a simple tracking system to quantify crossbar benefits:
- Record breakages per 1,000 shipments before and after crossbar deployment
- Note handling conditions, carrier and route for each incident
- Analyse patterns to refine material choice or packing method
Clear data drives continuous improvement and justifies further packaging investments.
Cost savings analysis
When you calculate the total cost of ownership, include:
- Cost per carton including crossbars and inserts
- Savings from reduced product loss and warranty claims
- Labour efficiencies from faster packing and fewer repacks
Many operations see a return on investment within a few months, thanks to lower claims and happier customers.
Frequently asked questions
What types of products benefit from crossbars?
Any fragile items that are shipped in multiples—wine and beer bottles, glass jars, cosmetic vials or electronics—can benefit from crossbars. They are ideal when you need consistent spacing and reliable side-impact protection.
How do I measure the right crossbar size?
Measure the interior length and width of your carton, then divide by the number of compartments needed. Share these dimensions with your supplier. They will adjust for material thickness to ensure a snug fit.
Can crossbars be recycled?
Yes. Most corrugated and honeycomb cardboard crossbars are fully recyclable in standard cardboard waste streams. Check for any laminate or coating that might require special disposal.
Do crossbars work with automated packing lines?
Absolutely. You can specify pre-creased crossbar sheets or automated feed-in rolls that dispense separators at line speed. Coordinate with your line integrator to match feed-in and placement tooling.
How much can crossbars reduce breakage?
Results vary by product and transport conditions, but many companies report a 40–70% reduction in breakages when switching from loose fill or foam to a combined crossbar and insert system.