custom inserts

custom inserts are trays, dividers, platforms and shaped holders made to fit inside a specific box and hold a specific product in position. They stop movement in transit, separate items that could damage each other and present the contents neatly when the box is opened. UK brands use them for cosmetics, candles, bottles, electronics, jewellery and gift sets where both protection and presentation matter.

What custom inserts do inside a box

An insert does three jobs at once. It locates the product so it cannot slide, rattle or strike the sides of the box. It creates space between multiple items, which protects glass, labels and delicate finishes. It also sets the order in which a customer sees the contents, which is why gift sets and subscription boxes look arranged rather than packed. A plain box with a well fitted insert often protects better than a larger box filled with loose cushioning.

Inserts are designed from the product outward. The designer works from exact product dimensions, the weight of each item and the internal size of the chosen box. Our custom mailer boxes with inserts pair the outer box and the insert as one specification, so the two parts arrive ready to work together.

Materials used for custom inserts

Card and corrugated board inserts are widely used because they are recyclable with the box, can be printed and fold flat for storage before use. Foam inserts cushion very fragile or high value items and can be cut to complex shapes, though they are harder for customers to recycle. Moulded pulp offers shaped protection with a natural look, and rigid board trays suit premium boxes where the insert is part of the presentation.

Insert styles for different products

Divider grids suit bottles, jars and candles sold in sets. Die cut platforms with shaped apertures suit cosmetics, electronics and tools, holding each item in its own position. A simple raised platform can lift a product toward the lid for a better reveal, while a tray and lid combination works well in rigid boxes for jewellery and watches.

Measuring a product for an insert

Measure each item at its widest and tallest points, including caps, pumps and cables that will travel with it. Note which surfaces are fragile or easily scuffed, because those faces should not press against another item. Share photographs alongside measurements when you enquire, as shape details such as tapered bottles affect how an aperture is cut.

Ordering custom inserts with your boxes

Inserts perform best when they are ordered with the box they will live in, because a small change in board thickness changes the internal space. They are used across custom rigid boxes, candle mailer boxes and many other formats in our range. Custom Postal Boxes offers low minimum order quantities, free design support and free UK delivery, with pricing based on size, material and quantity.

Right fitting inserts also reduce the need for extra void fill, which supports the aim in the GOV.UK packaging producer responsibilities guidance to reduce unnecessary packaging. To start, send your product dimensions through our contact page and tell us how many items each box must hold.

FAQs about custom inserts

What is the difference between an insert and void fill?

An insert is a shaped part made for one product and box, holding the item in a fixed position. Void fill is loose material such as paper or air cushions that fills empty space generally. Inserts give more precise protection and a neater presentation.

Which insert material is best for fragile items?

Foam gives the softest cushioning for very fragile or high value goods. Corrugated board inserts give firm support and are recyclable with the outer box, so they suit most cosmetics, candles and gift sets. The product weight and finish usually decide the choice.

Can inserts be printed with branding?

Yes. Card and board inserts can be printed with logos, instructions, care notes or reorder prompts. Printed inserts are a practical place for information because the customer sees them at the moment they lift the product out.

Do inserts have to be ordered with the box?

It is strongly recommended. An insert is cut to the internal dimensions of a specific box, and board thickness affects that space. Ordering both together ensures the fit is correct and the product sits at the intended height.