An overview of the standard customizations available for custom box inserts.
The size and print for all these images is for reference only. You can fully customize the dimensions and what to print on your packaging.
Custom Box Inserts
Ideal for products needing a sturdy solution, these inserts provide a snug fit and can be printed to enhance the unboxing experience.
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Customizable Box Inserts
Fully customizable
Packaging inserts or packaging inlays keep your products secure and organized. Customize your paper and cardboard inserts with full print and designs that pair beautifully with your boxes.
Sturdy and secure
Custom box inserts are tailored to the precise size of your products, keeping them secure in transit while giving your customers a truly elevated unboxing experience. Opt for foam inserts if you need additional protection for fragile items.
High quality & affordable
Paper and cardboard box inserts are printed with offset printers that yield sharp and vivid outcomes, all at an affordable price point.
Showcases: custom box inserts
Other than product protection, custom inserts allow you to present your products beautifully during the unboxing process. If you have multiple items in one box, packaging inserts are a great way to position each product just the way you'd like. Get inspired by how brands use custom box inserts to achieve incredible brand experiences.
Perfectly Engineered Packaging Solutions
Creating an ideal insert design is more than meets the eye. Because products come in various shapes, sizes, and weights, it becomes crucial to use the appropriate materials, construct robust structures to securely accommodate each item, and ensure a precise fit between the insert and the outer box to complete the package.
No need to hire an in-house packaging engineer or buy expensive equipment. Through our structural packaging design service for inserts, we'll help bring your product vision to life.
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Hear what our clients have to say
Rusty's Pet Essentials
Working with PackMojo was an absolute breeze. It can be intimidating working with a company overseas but Vincent helped me execute my project perfectly. The final custom boxes and inserts are incredible!
Bluecorn Beeswax
PackMojo is now our go-to for custom corrugated boxes! From packaging development through production, freight and quality assurance, their project management, expertise and professionalism are simply unmatched. Plus, they offer a wide variety of recycled and eco-friendly materials, in addition to a tree planting program. Highly recommend!
Aenomaly Constructs
Working with Wendy and the PackMojo team has been a dream. Very fast response time, detailed, and accurate. Could not be happier with the service and the packaging. Highly recommend!
Common Insert Structures
With custom box inserts, there's no one size fits all solution. The structure of an insert is tailored to accommodate the size, weight, and position of each product, ensuring optimal security. Here are some examples of common paper or cardboard based insert structures:
- Box Insert (no backing): typically used for products that can sit directly at the base of the box and don't need to be elevated. These types of inserts are also ideal for products of the same size.
- Box Insert (with backing): typically used for products of similar sizes that need to be elevated to fit securely in the insert, or need extra support.
As part of the structural design process, our team will help determine the best insert structure for your products.
Technical Specs: Custom Box Inserts
Corrugated Materials
Box inserts that are corrugated (the wavy lines in cardboard) are stronger and ensure the insert is sturdy. Corrugated inserts are typically used for heavier items, fragile items, or items that will be shipped and need extra cushioning/protection.
E-flute
Most commonly used option and has a flute thickness of 1.2-2mm.
B-flute
Ideal for large boxes and heavy items, with a flute thickness of 2.5-3mm.
Designs are printed on these base materials which is then glued to the corrugated board. All materials contain at least 50% post-consumer content (recycled waste).
White Paper
Clay Coated News Back (CCNB) paper that's most ideal for printed corrugated solutions.
Brown Kraft Paper
Unbleached brown paper that is ideal for only black or white print.
Non-corrugated Materials
Box inserts that are paper based and not corrugated are typically used for lightweight, non-fragile items. These paper based inserts used a standard thickness of 300-400gsm, and contain at least 50% post-consumer content (recycled waste).
White Paper
Solid Bleached Sulfate (SBS) paper that yields high quality print.
Brown Kraft Paper
Unbleached brown paper that is ideal for only black or white print.
Foam packaging inserts are designed to keep products safe and secure during transportation. They are customizable, providing a snug fit that protects fragile or delicate items from potential damage.
PU Foam
Open-cell Polyurethane foam is softer and more flexible, resembling the material of a sponge. Available in black or white.
EVA Foam
Closed-cell Ethylene Vinyl Acetate foam is more rigid and dense than open cell foam, resembling the material of a yoga mat. Available in black or white.
All packaging is printed with soy-based ink, which is eco-friendly and produces much brighter and vibrant colors.
CMYK
CMYK is the most popular and cost effective color system used in print.
Pantone
For accurate brand colors to be printed and is more expensive than CMYK.
Coating
Coating is added to your printed designs to protect it from scratches and scuffs.
Varnish
An eco-friendly water-based coating but doesn't protect as well as lamination.
Lamination
A plastic coated layer that protects your designs from cracks and tears, but not eco-friendly.
Finishes
Top off your packaging with a finish option that completes your package.
Matte
Smooth and non-reflective, overall softer look.
Glossy
Shiny and reflective, more prone to fingerprints.
Satin
Semi-shiny, in between a matte and glossy look.
Soft touch
Looks like a matte finish, but feels like velvet.
Custom box insert order process
A single platform to get quotes and place orders, with dedicated support every step of the way.
Customize your packaging
Go to the PackMojo platform to customize the size, materials, print, and finishes of your inserts.
Get estimates & start structural design
Place your order
Upload artwork
Track order progress
Frequently Asked Questions
Can't find what you're looking for? Check out our help center.
What is the minimum order quantity for custom box inserts?
Minimums starting from 300 units per size or design when ordered with the outer box. Standalone box inserts start with an MOQ of 500 units.
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How do I get a quote for inserts?
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Get Custom Packaging Inserts Today
Continue to the PackMojo platform to customize your boxes and inserts and get an initial quote.