Custom Corrugated Box Dividers Cut to Fit Your Box

What are corrugated box dividers?

They are flat strips of corrugated board cut with slots. Each strip slots into the strips running the other way, and the result is a grid that stands up inside a box.

The grid turns one open box into many small compartments. Every item has its own space, so nothing touches its neighbour.

Our photos show grids of three, five, twelve and sixteen cells inside mailer boxes. There is also a punched corrugated holder with six round holes for small bottles or vials.

Which type of divider do I need?

The layout depends on what you pack and how heavy it is. This table covers the common options.

How do I measure for box dividers?

Start with the inside length, width and height of the box the dividers will go in. If you are ordering the box from us too, we size both together.

Then measure the widest point of one product. Each cell should be a few millimetres larger so items slide in without forcing.

Remember that every divider wall takes up space. In B flute each wall adds about 3 mm, so a row of four cells needs about 9 mm more than the products alone.

Finally, count how many items you want in each row and column. Our guide to taking inside box measurements explains where to place the tape.

Which board should the dividers be?

Light items, such as sample bottles, are fine with E flute at about 1.5 mm. It is thin, so it leaves more room for the products.

For jars and standard bottles, B flute at about 3 mm or C flute at about 4 mm gives a firmer wall between cells. Most beer and sauce bottle dividers fall into this range.

Heavy glass, such as wine bottles, suits double wall BC board at about 7 mm. It adds cushioning as well as strength, and pairs well with a double wall outer box.

The board for the dividers does not have to match the outer box. A double wall outer carton with single wall dividers inside is a common pairing for jars.

If you are unsure, send a photo of the product and its weight. We will suggest the flute on the quote and explain the reason in a line or two.

Should box dividers be printed?

Most dividers are left plain, because they sit inside the box and are mainly there to protect. Plain kraft is the most common choice.

If the dividers show when the box is opened, as in a gift set, printing can be worth it. We print one colour, two colour or full colour CMYK, and white board gives a clean look like the pink-lined box in our photos.

Finishes such as lamination or foil are rarely needed on dividers. Save those for the outer box.

One useful middle ground is a single colour number or label on each cell. It helps pickers fill mixed sets in the right order.

Packing tips

Assemble the grid on a flat table first, then lower it into the box in one piece. Trying to build it inside the box usually ends with a bent strip.

Load the heaviest items into the corner cells first. That keeps the box balanced while you fill the middle.

If you pack mixed sets, tape a filled example to the bench wall. New staff can copy the layout without asking.

For glass, wrap each bottle neck with a little paper if it rises above the divider height. Close the box and give it a gentle shake to check nothing rattles.

Can I order dividers on their own?

Yes. If you already have boxes, send us their inside size and we will cut dividers to fit them.

It helps to measure two or three of your boxes, not just one. Boxes from different batches can vary by a millimetre or two, and dividers should suit the snuggest of them.

Many customers order the box and dividers together, though. Sizing both at once avoids gaps and saves a measuring step.

Mailer boxes with built-in grids, as in our photos, are a neat option for sending sets by post. See mailer boxes with fitted inserts for that style.

How do dividers protect glass?

A common cause of breakage in a box of bottles is glass striking glass. A divider wall between them removes that contact.

The corrugated fluting also gives a little cushion. When the box is bumped, the board flexes slightly instead of passing the knock straight through.

Add a layer of board or paper under the grid for extra protection at the base.

Dividers also help the box itself. The grid braces the side walls from inside, so a filled box keeps its shape better when another box is stacked on top.