Custom Corrugated Inserts Die Cut Around Your Products

What is a corrugated insert?

A corrugated insert is a shaped piece of fluted board that lives inside a box and holds the contents in place. It is cut flat on a die, then folded into a tray, a platform or a riser.

The key part is the cut-out. Each hole or well is sized to one product, so it cannot slide around. Our photos show black, white and kraft inserts with round wells for bottles and shaped wells for a mixed skincare set.

Inserts are made to order rather than picked from a shelf. You will find them in our box inserts and packing supplies range.

Which insert style suits my products?

The shape of the product decides the style. Tall bottles need deep wells, while flat items need a platform to stop them sliding.

How do I give you the right measurements?

We need two sets of sizes. The first is the inside length, width and height of the outer box. The second is the size of every product that goes in the insert.

Measure each product at its widest point. For a bottle, that is usually the shoulder or the cap. For a jar, it is often the lid. Write the height too, because it decides how deep each well must be.

If the shape is unusual, send a photo of each product beside a ruler. It shows us curves, handles and pumps that a tape measure can miss. Our designers then draw each well around the real outline.

Which flute should a corrugated insert use?

E flute, at about 1.5 mm, is the most common choice. It cuts crisp edges, folds tightly and prints well, so it suits neat retail sets.

B flute, at about 3 mm, gives more cushion and suits glass jars and heavier bottles. C flute, at about 4 mm, is used for deep pockets in larger shipping boxes. The guide to corrugated board flutes compares them side by side.

If in doubt, think about the heaviest item in the set. A 30 ml serum is happy in E flute. A full jar of honey or a glass candle is better held in B flute, or in two layers of E flute glued together.

Can inserts be printed to match the box?

Yes. Many brands print the insert in the same colours as the outer box, so the opening feels like one design. A black insert inside a black mailer is a popular look, as is a white insert under a kraft lid.

We print one colour, two colour or full colour CMYK, inside and outside. Matte lamination, spot UV and foil stamping are available on the top panel. You can also print a short thank-you message or usage note around the wells.

Which mistakes make an insert fail?

Cutting wells to the exact product size is the commonest error. Board has a little spring, and a well with no clearance makes products hard to push in and harder to lift out. Add 1 to 2 mm, and a thumb notch for items that sit deep.

Another mistake is forgetting the lid. If the insert plus the product is taller than the box, the lid will bulge. Check the total height before you sign off the proof. Changing the product later, even by a few millimetres, also means a new insert, so confirm final packaging sizes first.

Should I buy the box and insert together?

It is usually the safer route. When we size both at once, the insert edges sit flush with the box walls and the wells line up with the lid.

A matching outer is often one of our mailer boxes with fitted inserts. If you already have boxes you like, we can still cut inserts to suit them from your inside measurements.

Do inserts make sense for small runs?

Yes, as long as the products are fixed. An insert is cut on a die made for your layout, so it repays the effort when the same set ships again and again. A seasonal box for Easter or Valentine's Day can still work well, provided the contents are settled before you order.

If your products change every month, a simpler option may suit you better. Loose fill such as crinkle paper shred for gift boxes adapts to any mix of items. Some brands use both: an insert for the hero product and shred around the extras.

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

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

Inserts start from £0.25 per unit, and the written quote confirms your price. Send the box inside size, each product size, the board colour and how many you need.

Ask for prices on our quick trade quote page, or set things up in Design Your Box. Prefer to talk it through? Email info@ordercardboardboxes.co.uk, or send a WhatsApp with your product photos. If any inserts arrive damaged or misprinted, send photos within 10 days for a reprint or refund.

We send a free digital proof of the insert layout first, with each well marked. Once you sign it off, the inserts are made in 4 to 6 business days. Tracked delivery then takes 2 to 3 business days.

Inserts ship free to any UK address. Inserts arrive flat, so a large order takes up little room until packing day.