Custom Corrugated Inserts & Dividers
Paper-based fitments developed with the outer case to control product position, separation and the sequence in which items are revealed.
- Paper-Based Fitment
Overview
Corrugated inserts and dividers organise the space inside a box. They can separate repeated units, create cells around bottles or components, or fold into supports that stop a product moving without turning the whole pack into a mixed-material assembly.
Fit depends on the relationship between the insert, the product and the outer case, so the three are developed together. Cavity positions, loading sequence, contact points and product movement are reviewed on a fully loaded sample. Any transport-performance requirement then has to be agreed and assessed against the intended journey rather than inferred from material alone.
What to decide for this format
Separation & Loading Sequence
Define which items must not touch, how operators load them and whether the divider arrives pre-assembled or flat.
Outer Case Relationship
Develop the insert against the actual case dimensions so its folds, cells and supports stay located after packing.
Board & material options
Natural Brown Kraft
Unbleached brown fibre, the recycled-content standard.
The lowest-processing option we stock. Remember that the brown ground shifts every ink laid over it — colours need proofing on the actual stock, not on white.
White Kraft
Strong uncoated white fibre with a natural surface.
Reads honest rather than glossy, and takes one or two spot colours well. Recycled and FSC-certified grades are available where a materials policy applies.
Recycled Content Board
Post-consumer fibre, visible in the surface.
The speckle is the point — it reads as recycled without a label saying so. Colour varies between batches, which has to be accepted up front.
Coated One Side (C1S)
Coated on the printing face, uncoated on the reverse.
The default carton and wrap board. You are paying for coating only where the print goes, so it is the economical choice whenever the inside face is not seen.
Finishing options
Die Cutting
Custom shapes, windows and cut-outs.
Windows, shaped lids, handle apertures and label outlines. A window can be left open or patched with clear film depending on whether the product needs protecting.
Aqueous Coating
A water-based protective coat applied in-line.
The low-cost seal on cartons and shippers. Water-based, so it stays inside a recyclable mono-material specification.
Spot UV
Gloss varnish applied to selected artwork elements.
Highest contrast over a matte or soft-touch base. On a gloss laminate it barely reads — the base finish decides whether spot UV is worth paying for.
Anti-Scuff Lamination
A matte film formulated to resist marking.
Ordinary matte film scuffs on dark artwork in transit. This is what you specify when the pack is dark and ships a long way.
Materials
Single-Wall Corrugated
The default for retail packs and lighter e-commerce goods, balancing strength against cube and cost.
Double-Wall Corrugated
For heavier products, tall stacking and long export transit where a single wall would crush.
Kraft Liners
Brown or white kraft outer liners, printed direct where one or two colours is all the job needs.
Recycled & FSC-Certified Board
Recycled-content and certified board with water-based inks — corrugated is the easiest part of a pack to make genuinely circular.
Printing & Finishes
Die Cutting & Creasing
Cells, partitions and folded supports are cut and creased to the approved insert layout.
What you can customise
- Cell count, product orientation and loading sequence
- Corrugated grade and fold construction
- Contact points and clearance around the actual product
- Fit with the finished outer case
- Flat or pre-assembled supply format
Specifications
| Minimum order quantity | Standard cartons from 1,000 units |
|---|---|
| Production lead time | 15–20 working days after artwork approval |
| Converting line | Fully automated line integrating printing, laminating and gluing |
| Print processes | Offset litho-lamination on the Rapida 106; six-colour flexo and water-based printing for direct liner print |
Terms for this specification
- Sampling
- Presentation-quality sample in 5–7 working days. The sample cost is credited against your first approved production order.
- Colour matching
- Pantone references and physical samples are used where the selected print process supports them. The approval method follows the substrate, artwork and process.
- Certifications
- ISO 9001, ISO 14001:2015, ISO 45001 and China Environmental Labelling (Ten-Ring). ISO 22000 applies to eligible food-contact work.
- Sustainable options
- FSC-certified or recycled-content paper and board, water-based inks and adhesives, and fibre-based fitments are available where the selected construction supports them.
What drives the cost
We do not publish a price list, because no two specifications are alike. The levers that decide a quote are consistent, though.
Quantity
Most of the cost of a print job is set-up — plates, dies, make-ready, the first good sheet. Doubling a run rarely doubles the price, which is why it is worth asking for two or three volumes on the same quote.
Structure
A rigid box is formed, wrapped and often assembled by hand; a folding carton is die-cut and glued in one pass. Structure is usually the single biggest difference between two otherwise identical packs.
Material
Board grade and wrap stock. Specialty and textured papers cost more per sheet, but can replace a finishing pass — sometimes the cheaper route to the same effect.
Finishing passes
Each of foil, emboss, spot UV and lamination is a separate pass through a machine. Two effects cost roughly twice one, so the question is always which effect earns its place.
Tooling
Dies, emboss plates and foil blocks are one-off costs carried by the first order and reused on every repeat. Repeat runs of an approved specification are materially cheaper than the first.
Design & artwork
From an artwork check, through a dimensioned dieline and print-ready files, to a full concept package across a range — done by the factory that will make it.
Applications
Repeated Units & Multipacks
Cells and partitions used to separate repeated products inside a shared case.
Bottle & Component Separation
Folded corrugated fitments considered where locating and separation are the primary tasks.
E-Commerce Sets
Product-specific layouts developed with the mailer and checked on the complete loaded sample.
How it is made
Product, case & journey review
Product geometry, contact limits, loading sequence, outer-case dimensions and intended journey are reviewed together.
Insert layout
Cells, folds and support points are developed against the product and finished outer case.
Sampling
A cut and folded insert is loaded with the actual products wherever possible so fit and movement can be checked.
Die cutting & forming
The approved layout is die cut and creased, then folded or assembled to the specified supply format.
Inspection & packing
Dimensions, folds and count are checked against the approved sample before packing with the outer-case programme.
Why Yuan Packaging
- Fully automated line integrating printing, laminating and gluing — serving publicly listed companies
- Litho-lamination and flexo under one roof, so print method follows the job rather than the equipment
- Corrugated made where the retail pack inside it is made — one specification for the whole shipment
- Recycled and FSC-certified board with water-based inks for mono-material recyclable packs
Frequently asked questions
Can corrugated dividers replace foam inserts?
They may be suitable when separation and location are the main tasks. A loaded sample checks fit and movement; if impact or transit performance is required, the acceptance method and journey conditions need to be defined separately before the material is approved.
Should the insert be designed separately from the box?
No. The insert consumes internal space and transfers load into the case, while the case controls where the fitment can bear. Developing both together avoids a divider that fits on screen but moves or bows after packing.