Folded Product Inserts

Choosing the Card

Folding boxboard is the usual choice for light to medium products such as cosmetics, candles and small jars. It folds crisply and can be printed. Corrugated board gives more strength for heavier items, such as glass bottles or multiple products, and absorbs knocks better. Kraft board suits natural brands and matches kraft boxes.

Board thickness affects how firmly the insert holds. We will suggest the right grade based on the product weight and how the box will be shipped.

Grain direction matters for folded inserts. We set the card grain so the main folds run the right way, giving cleaner creases and stronger platforms that do not sag over time.

If inserts will be printed on one side only, we usually print the face seen by the customer and leave the folded-under parts plain to keep costs down. Our board guide has card and corrugated grades explained so you can judge the weight.

Printing on the Insert

Inserts can be left plain or printed. A printed insert is a good place for a short message, product names, instructions or your logo. Some brands print the insert in a contrasting colour to the box, which creates a striking reveal when the lid is lifted. Even a single colour print on a plain insert makes the inside of the box feel more considered.

Printed inserts can also carry practical information, such as the order in which to use products in a routine or a reminder to keep the box. These small notes add value without adding extra printed pieces. A printed insert works best with print matched to the outer box so the colours agree when the lid lifts.

Designing an Insert for Your Products

Start with the box you plan to use and the products that go inside. Measure each item carefully, including caps, pumps and labels. Decide how you want the products arranged and which item should be seen first. We then design an insert that fits both the box and the products, with finger notches where needed so items lift out easily.

Send us samples if your products have unusual shapes. A physical sample helps us get the fit right first time.

If you plan to change products in the future, mention it; we can design an insert that suits a range of sizes.

Allow a small tolerance in the cut-outs. Products vary slightly from batch to batch, and a cut-out that is too tight can make packing slow and frustrating.

Test a first batch by packing a few real orders, then adjust the design if needed before ordering in larger quantities.

Think about the packing process as well as the finished look. An insert that takes several folds may look impressive but slow down a packing bench; a simpler design that folds in a few seconds can save hours on a large order.

When products are light, a thinner board keeps parcel weight down without losing hold. Our guide on how to measure each product for its cavity covers caps, pumps and lids.

Where Folded Inserts Are Used

Skincare and beauty brands use them in gift sets to hold jars and tubes. Candle makers use them to keep candles upright in shipping boxes. Food and drink brands use them for gift boxes holding jars, bottles and treats. Electronics brands use them for accessories such as chargers and cables. Subscription boxes use them to keep monthly products tidy.

They also suit small businesses packing by hand, as they fold quickly and need no special equipment.

Charities and event organisers use them in welcome packs and goodie boxes, where several small items need to sit neatly together.

Online retailers who send fragile ceramics or glassware use suspension-style inserts to hold items away from the box walls, reducing breakage in the post. Online sellers use the same folds in e-commerce packaging inserts for mailer boxes.

Send the Box's Inside Measurements and a Photo of the Products Laid Out

A folded insert is designed twice: once to fit the box and once to fit the products, so we need both. Measure the inside of the box, length, width and depth, then lay the products out in the arrangement you want and photograph them from above with a ruler in shot. That shows us which items need a slot, a platform or a cradle, and whether one insert can cover several product sizes. Tell us the weight of the heaviest item, because glass usually moves the insert from card to corrugated board. If the insert will be printed, say which faces are seen when the lid opens, and whether a retail insert with a printed face would do a better job than a plain one.

With the measurements, photo and quantity, a custom quote comes by email within one working day, and the free proof includes an insert drawing. Production takes 4 to 7 working days after approval, inserts arrive flat by tracked courier to UK mainland addresses, and misprinted or wrongly cut inserts reported within 10 days are reprinted or refunded. We keep the drawing on file so a small adjustment later is quick.