Custom Corrugated Inserts for Bottles, Jars and Sets

What are corrugated inserts and what do they do?

A corrugated insert sits inside a box and keeps the contents from moving. We cut it flat on a steel die, then it folds into a tray, a deck or a set of risers.

The cut-outs do the real work. Each opening is sized for one product, so a bottle cannot roll into a jar. Browse the wider packing supplies and inserts range to see what else pairs with them.

Every insert is made to order. There is no stock size to pick off a shelf.

Which insert style fits my products?

Product shape picks the style. Tall bottles need deep pockets, while flat goods need a deck or slots to stop sliding.

What sizes do I need to send you?

We work from two sets of numbers. One is the inside length, width and height of your shipping box. The other is the size of each product.

Measure every item at its widest point. For a bottle, that is often the shoulder or cap. For a jar, check the lid. Note the height too, since it sets the pocket depth. Our steps for measuring a box cover the outer carton.

Odd shapes are easy to handle. Snap a photo of the item next to a ruler, and our designers trace the real outline.

Which flute works best for an insert?

E flute, about 1/16 in thick, is the usual pick. It cuts clean, folds tight and takes print well, which suits tidy retail sets.

B flute, about 1/8 in, adds cushion for glass jars. C flute, about 5/32 in, handles deep pockets in larger cartons. Our corrugated flute comparison guide lays the three out together.

Think about your heaviest item first. A small serum bottle sits happily in E flute. A full jar of preserves wants B flute or two glued layers.

Can I print on the insert?

Yes. Many brands print the insert in the same palette as the box, so opening it feels like one design. A black insert in a black mailer looks sharp, and so does white under a kraft lid.

Choose one color, two color or full color CMYK. Matte or gloss lamination, spot UV and foil stamping can go on the top sheet. You can also add a short thank-you note or care tip between the pockets.

Use Design Your Box to place your logo and see the layout before the proof.

What mistakes cause an insert to fail?

The biggest one is cutting pockets with zero slack. Board has some spring, so a pocket that matches the product exactly grips too hard. Allow about 1/16 in of clearance, plus a finger notch for deep items.

Another is ignoring total height. If the insert and product are taller than the box, the lid bulges. Check the stack height before you approve the proof.

Last, a product change means a new die. Even a small tweak to a bottle shape can call for a fresh cut, so lock your final items first.

Should I order the box and insert together?

Usually yes. When both are sized at once, the insert edges sit flush against the walls and the pockets line up under the lid.

A matching outer could be one of our mailer boxes with built in inserts. Already have cartons you like? Send the inside dimensions and we cut the insert to suit.

Are inserts worth it for low volume orders?

They can be, if the product set stays fixed. Minimums are low and quoted per job. A holiday box for Valentine's Day or Thanksgiving gifting works well once the contents are final.

If your items change monthly, loose fill may be easier. Paper like crinkle paper for gift boxes adapts to any mix. Some sellers combine both, with an insert for the star product and shred around the extras.

Tell us how often your set changes, and we will suggest the practical route.

How do I order corrugated inserts and how long do they take?

Pricing starts from $0.30 a box, and the exact figure is sent in the quote by email within one business day. Include your box inside size, each product size, the board color and your quantity. Request one through our quote request form.

You can also call (503) 461-4788, email info@ordercardboardboxes.com or send product photos by WhatsApp. We are available Monday to Friday, 9 am to 6 pm Eastern.

Before anything is cut, you get a free design proof with every pocket marked. Once you sign off on that proof, your order is made in 4 to 6 business days.

Shipping is free and tracked to any US address, and transit takes 2 to 3 business days. Inserts travel flat, so a big order uses little space until packing day. Report damage or misprints within 10 days with photos for a reprint or refund.