Custom Insert Trays.

Board covers most e-commerce orders, foam absorbs shock best, pulp gives a plastic-free cushion and thermoform makes precise seats at low tooling cost. Board wins most often because it recycles with the box and photographs well.

We'd move to EVA foam for heavy or fragile items, and to moulded pulp when the brief rules out plastic but still needs cushioning.

We measure the product itself, cut the insert to that, and only then work out the box dimensions. Working the other way round leaves gaps that let items shift and hit the wall.

A good fit holds the item firmly yet lets it come out without a struggle. Too tight is a failure too, because customers tear the insert getting at what's inside. We test every die loaded with real product, since an empty insert can't show you any of that.

Yes, a multi-cavity insert holds each piece of a kit in its own shaped seat. The layout also sets the order things are seen, so the main item can sit in the centre with accessories around it.

We plan the reveal order with you, then cut and test the full layout in one sample. Packing a kit into a fitted layout is also quicker than wrapping loose pieces in tissue.

Board inserts can be printed or made from colour-matched stock, and foam or thermoformed inserts can be flocked for a velvet surface. Wrapped foam, covered in paper or fabric, gives a premium platform with no foam edges showing.

A colour-matched board platform carries the brand colour into the box interior. Plain kraft or white coated board costs less and keeps the interior quiet.

The insert is sized to the inside of the host box and to the product, so there are no standard sizes. We need the box's inside dimensions or its dieline, plus the product's dimensions and weight.

If the box isn't made yet, we'll design the two together. That usually gives a tighter result than fitting an insert into a box chosen first.

Insert trays have a 500-unit minimum, whichever material they're made from. Most customers order inserts alongside the boxes they go into, at matching quantities.

If you already have boxes from another supplier, we can make the insert alone to fit them. Send a couple of the boxes so we cut to what's actually on your shelf.

Yes, a fit sample cut to your product takes 5 to 7 business days, and it's the step we'd least want to skip. After approval, production runs 7 to 10 business days, or 5 to 7 on rush.

The sample fee is credited when the order goes ahead. Small die adjustments after a first sample are normal.

A board insert inside a board box is the easiest, because the whole pack goes into one recycling stream. Moulded pulp is also paper-based and goes the same way.

Foam and thermoformed plastic have to be separated from the box before recycling. If the brief puts weight on sustainability, we'd push for board or pulp and use foam only where the protection really needs it.