Inserts and void fill

Damage happens when the product moves. An insert that holds the product in place is nearly always more effective, and cheaper over time, than adding more void fill.

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Inserts and void fill in moulded pulp and board beside an open box

Material choice

Board inserts: light, printable and easy to recycle with paper.
Moulded pulp: good shock absorption and precise fit, requires tooling.
Foam: best cushioning for heavy or fragile products, harder to recycle.
Paper fill and honeycomb: simple volume fill without moulds.

Fit and tolerance

An insert should hold the product without binding. We normally allow 0.5-2 mm tolerance depending on material and product hardness, and check that the product lifts out without the insert coming with it. Edges are often chamfered to make removal easier.

Sustainability trade-offs

Board and moulded pulp can usually go into paper recycling, which is a design advantage. We describe material choices as exactly that, design choices; verified environmental properties and certifications come from material and supplier documentation, not from us.

Process

Product measurement, sample insert, adjustment and approved specification.
MOQ around 250-300 units; pulp moulds need higher volume to pay off.
Lead time normally 6-8 weeks after confirmed design.

Close-up of a board insert cavity and the fibre structure of the material

Material, structure and finish in detail

We review board quality, thickness, fit, print technique and finishing with you and turn it into a specification a supplier can produce against.

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FAQ

Frequently asked questions

Board or moulded pulp?: Board for light products and small volumes, pulp when the shape is complex or cushioning needs to be better.
Can the insert be printed?: Board inserts can be printed; pulp only to a limited degree. A printed surface under the product is often enough.
How do I know protection is sufficient?: Through samples and, where needed, drop testing at the supplier. We start from weight, shape and transport mode.
Can you replace plastic fill?: Often yes, with board, pulp or paper fill. The protection level must be verified in samples before switching.

Custom insertsA custom insert does two things at once: it keeps the product still and decides the order in which the unboxing happens. Both come down to millimetres.Read more E-commerce packagingIn e-commerce the packaging carries both the brand and the transport. Dimensions, closure and void fill decide freight cost, damage rates and how the unboxing feels.Read more SustainabilityWe separate two things: design choices we can influence, and verified environmental properties that come from material and supplier documentation. We issue no certifications of our own and promise no environmental outcomes.Read more MaterialsMaterial choice drives both feel and cost. The same structure can feel entirely different depending on whether the surface is uncoated, laminated or wrapped in a speciality paper.Read more

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