At first glance, adding packaging may appear to be adding cost, but in most cases, utilizing internal packaging in the box you ship out can dramatically reduce your overall costs. Beyond increasing profitability there are many good reasons to utilize partitions, dividers, and die cut inserts. They include:
- Protecting products during shipment and preventing “product to product” or label damage
- Reducing labor cost and increasing productivity by eliminating time consuming loose void fill or protective wrap (bubble, foam, etc.)
- Enhancing the customer experience by creating a better presentation
There are three basic types or categories we are focusing on in this blog post:
Whether they are made of corrugated or paperboard, these are typically vertical in design and can be made in just about any configuration you may need. Examples: 2×2 = 4 cell, 4×3 = 12 cells, etc.
Even though they are most commonly used in the bottled beverage industry to separate glass bottles, the photo showing coffee “K-cups” demonstrates how they can bring order to a box and product that might otherwise be difficult to arrange and present to your customer.
They are easily made to any size WITHOUT any type of tooling or cutting die required. The minimum for most partitions is 1,000, but that MOQ can vary depending on size and material type.
Partition tip: Pay the few cents more to have your partitions pre-assembled. The automatic equipment used at the plant adds minimal cost and saves you hours of costly labor and time when you are trying to meet a box deadline.
The best way to describe a divider is an open top, horizontal partition. These are used whenever product visibility is important. Products can be separated for protection and elimination of damage while they are neatly arranged for the customer’s view delivering that retail experience in an e-commerce package.
Dividers can also be made of paperboard or corrugated, in either white or standard brown. For most, the MOQ is 1,000 and they usually do not require design time and can be produced quickly.
Divider tip – avoid the temptation to add cut outs, holes, slots, etc. so you can avoid custom tooling or cutting dies. If you apply the KISS principle, you keep the cost minimal while maximizing the benefits.
Die Cut Inserts
To create separation and protection with maximum visual impact, especially for unusual shapes and sizes, a custom die cut insert is the way to go. They do require a custom cutting die and may require design time, but typically the result is well worth the onetime costs. Packaging time can be greatly reduced with a product layout that is visually appealing.
Most inserts are made of corrugated board, in many cases E-flute gives a more attractive, less “industrial” look. They are also available in white or standard Kraft (brown) with a minimum 1,000 per configuration. Keep in mind the cutting die required for each configuration will likely cost hundreds of dollars. In addition, other than the simplest designs will require some time to create but we can usually give you an idea of what it will take over the phone.
In some situations an insert design MAY be able to hold different product combinations or counts. Talk to us about all of your products and we may be able to help you create a versatile, flexible insert or at the very least create different (multiple) inserts that fit in one universal shipping box.
Die cut insert tip: Complete the professional look of your die cut mailer by adding color and/or custom printed copy. The inserts are already being die cut so adding ink is surprisingly affordable.
Additional Internal Packaging Options
We offer one of the widest variety of internal packaging products in the industry. Other options include molded pulp, molded plastic trays, as well as various formulations of molded and die cut foam.
What is the best option for you? There are a number of factors including the product being shipped, the volume, your budget, and the look you are trying to achieve. If in doubt, call us at 630-551-1700 or contact us at Salazar Packaging for a no cost, no obligation review of your needs.