Custom Truffle Boxes: Sizing, GSM & Count Made Simple
What Are Custom Packaging Inserts and Why Do They Matter for Food Brands? TL;DR: Short version: it’s a shaped piece of cardboard, corrugated board, or foam that goes inside a box and pins a product to one spot so it can’t move around. Stops jars and bottles from knocking into each other on a truck, and honestly it also just makes a box look better the moment someone opens it. Do you always need one? No. One item that already fits its box snugly ships fine most of the time. Throw a second item in there, or anything glass, and the odds change fast. Already know you need one? Skip ahead to the spec steps. The Problem an Insert Actually Solves A jar of hot sauce goes into a box that’s two inches too roomy. Nobody catches it at the packing table because two inches doesn’t look like much on paper. Then the box gets loaded onto a truck, and every turn that driver makes, the jar slides, corner to corner, into whatever else happens to be riding next to it. Three days go by and it lands on someone’s porch cracked, or leaking through the bottom flap, or just loudly rattling in a way that makes the person nervous before the box is even open. That’s not really the carrier’s fault, if we’re being fair. It’s just what happens to anything that has room to move. And this happens a lot more than most people assume going in. A retail study that got passed around pretty widely a while back found that close to a quarter of online orders were packed badly enough to cause problems down the line, and damage ended up being one of the top reasons customers sent things back in the first place (Retail Dive). For a food brand, that’s not just an awkward refund. It’s someone’s first real impression of your product being a mess they had to clean off the inside of a box. What Is a Packaging Insert, Exactly? Strip the jargon away and it’s a piece of cardboard, corrugated board, or foam cut to the shape of whatever’s going into the box with it. Not a generic shape pulled off a shelf. The actual footprint of the product, give or take a bit of tolerance. Put the product in, and there’s nowhere left for it to go. People mix this up with crinkle paper or air pillows sometimes, but honestly those two are doing something pretty different. Void fill just occupies space. It doesn’t hold a product anywhere specific, it just keeps the box from feeling hollow when you shake it. An insert is cut and scored so the product physically can’t travel. Types of Packaging Inserts, and Where Each One Actually Fits Not every insert does the same job. Pick wrong and you usually don’t find out until a customer emails you about it a few weeks later. Rough breakdown below. Insert Type Material Crush Resistance Eco-Rating Best Use Die-Cut Insert Corrugated board or cardboard Moderate to high FSC-certified, fully recyclable Jars, bottles, multi-item food boxes Corrugated Divider E-flute or B-flute corrugated High FSC-certified, fully recyclable Fragile stacked items, glassware Foam Insert Molded or sheet foam High Not curbside recyclable Heavy or irregularly shaped products Cardboard Riser/Tray Chipboard or SBS board Low to moderate FSC-certified, fully recyclable Presentation-first gift or retail boxes Most food brands end up starting with die-cut. It’s precise, it recycles without a problem, and the price per unit stays reasonable even once you’re a few thousand units in. Foam really only earns its spot once a product’s heavy enough that cardboard alone would eventually compress under its own weight on a long route. Print On Papers makes custom packaging inserts in both cardboard and foam, cut to a product’s actual dimensions instead of rounded off to whatever stock size happens to be closest. So, Do Food Boxes Actually Need Inserts? Not always, and anyone insisting every box needs one is probably trying to sell you something you don’t need. A single bottle going into a box that was already sized for it tends to ship just fine with nothing extra inside. Where it falls apart is the gap between a product and the box wall, or multiple items sharing one box, or a product made of glass or ceramic that has basically no room for error. There’s a quick test that takes about ten seconds for this too. Pack the product the way you normally would, close the box, and give it a shake. If you can feel it move more than a few millimeters, it’s going to move a lot more than that once it’s actually on a truck, and at that point, taping the box tighter or going up a box size doesn’t fix anything. What fixes it is something that physically locks the product in place. Jarred and bottled goods almost always need one. So do bakery boxes with several delicate pieces riding together, subscription boxes shipping multiple SKUs at once, and gift sets pairing food with something that isn’t food. On the other side, a single-item order already going into a box that fits it well usually doesn’t need anything extra, and flexible packaging like bags or pouches rarely has enough empty space to be a problem in the first place How to Spec a Custom Insert for Your Box Get this wrong and you’re not fixing it with a quick email, you’re paying for a second production run. So it’s worth slowing down here. A fair number of brands spec custom packaging sleeves at the same time as the insert, since one covers the outside of the box and the other handles the inside. Doing both together usually means a single proof round instead of two separate ones, which is worth asking about if you’re ordering custom packaging supplies for the first time. Are Packaging Inserts Eco-Friendly? Depends which one you’re asking about. There’s no single yes or no that