The Guide to Custom Packaging Inserts for your business

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The Guide to Custom Packaging Inserts for your business

Custom packaging inserts are a powerful tool to elevate the look of your packaging, protect your products, and create a memorable unboxing experience for your customers. Whether you're shipping delicate items, luxury goods, or unique products, custom inserts can provide the perfect solution. In this ultimate guide, we'll explore the different types of custom inserts, the materials used, the design elements to consider, and the benefits they bring to your brand.

Custom Inserts Classification

When it comes to custom inserts, there is a wide range of options to choose from. Each type of insert offers unique benefits and is suitable for different products and packaging requirements. Here are some of the most popular types of custom inserts:

  1. Paperboard Inserts: Ideal for lightweight products like cosmetics and stationery, paperboard inserts provide an elegant presentation. However, they may not offer enough protection for fragile items.
  2. Corrugated Inserts: Made from corrugated cardboard, these inserts are perfect for heavy-duty packaging. They can handle fragile items like bottles and offer excellent protection during shipping.
  3. Rigid Chipboard Inserts: Rugged and durable, rigid chipboard inserts are suitable for shipping delicate items such as ornaments and perfume bottles. They can also be used to organize products inside the box.
  4. Foam Inserts: Foam inserts provide padding and protection for fragile items like glass, camera lenses, and jewelry. They are lightweight, cost-effective, and can be easily customized to fit different product sizes.
  5. Pulp Packaging Inserts: Made from recyclable materials, pulp packaging inserts are used for fragile items such as eggs and wine bottles. They offer excellent protection and are stackable for efficient storage.
  6. Mushroom Packaging: For those looking for sustainable options, mushroom packaging is a great choice. It is made from organic materials and can be molded to fit various products. After use, it can be added to compost piles.
  7. Molded Plastics: While not as environmentally friendly, molded plastics offer durability and flexibility. They can be molded to fit specific products and provide adequate protection during shipping.

Choose your right inserts

Selecting the right material for your custom inserts is crucial to ensure the safety of your products and reflect your brand values. Factors such as product fragility, sustainability, and budget should be taken into consideration. Let's explore some of the commonly used materials for custom inserts:

  1. Paperboard Inserts: These inserts are lightweight, easy to print on, and offer a polished presentation. They are suitable for small, lightweight items and can be customized with branding elements.
  2. Corrugated Inserts: With their durability and excellent protection, corrugated inserts are ideal for heavy or fragile products. They can be printed on and provide a professional look.
  3. Rigid Chipboard Inserts: Made from reinforced cardboard, rigid chipboard inserts offer robust protection for delicate items. They can be reused by customers and provide a premium look.
  4. Foam Inserts: Foam inserts are perfect for fragile items that require cushioning and protection. They are lightweight, customizable, and cost-effective.
  5. Pulp Packaging Inserts: Made from recyclable materials, pulp packaging inserts offer great protection for fragile items. They are versatile and stackable for efficient storage.
  6. Mushroom Packaging: This sustainable option is made from organic materials and is 100% biodegradable. It can be molded to fit various products and can be composted after use.
  7. Molded Plastics: While not environmentally friendly, molded plastics offer durability and flexibility. They are suitable for products that require extra protection during shipping.

When choosing the material for your custom inserts, consider the nature of your products, your brand values, and your budget. Opting for sustainable materials can also resonate well with environmentally conscious consumers.

Design Your Perfect Inserts

Designing a custom insert that fits your products perfectly and reflects your brand identity requires careful planning and consideration. Here are some essential steps to follow when creating the structural design for your custom insert:

  1. Measure the Dimensions: Start by determining the exact dimensions of your products. For regular-shaped items, simple measurements will suffice. However, for irregular-shaped products, you may need to send the physical item to the manufacturer for precise measurements.
  2. Avoid Over-Engineering: While you want your custom insert to provide adequate protection, avoid adding unnecessary weight or bulk to your packaging. Find the right balance between protection and efficiency.
  3. Consider Fulfillment: Ensure that the custom inserts can be easily assembled and inserted into the packaging. Choose a reliable fulfillment center to handle the process smoothly and avoid shipping mishaps.
  4. Enhance the Unboxing Experience: Make sure that customers can easily remove items from the insert without frustration. Consider how the packaging can be recycled or disposed of to minimize waste.
  5. Custom Printing and Design Elements: Use custom printing techniques to add branding elements, such as logos, colors, and messages, to your inserts. Consider different coatings and finishes to achieve the desired look and feel.

By carefully considering the dimensions, fulfillment process, and design elements, you can create a custom insert that not only protects your products but also enhances the unboxing experience and reinforces your brand identity.

Custom Inserts Benefits

Investing in custom packaging inserts can bring a multitude of benefits to your brand. Let's explore some of the advantages of using custom inserts:

  1. Robust Product Protection: Custom inserts are designed to secure and protect your products during shipping. They provide a snug fit and prevent damage, ensuring that your customers receive their items in perfect condition.
  2. Enhanced Presentation: Custom inserts elevate the overall presentation of your packaging. They help showcase your products and create a memorable unboxing experience. This can lead to positive word-of-mouth and social media sharing, boosting your brand visibility.
  3. Brand Recognition: Custom inserts provide an opportunity to reinforce your brand identity. By incorporating your logo, brand colors, and messaging, you create a cohesive and recognizable packaging experience. This can increase brand recognition and customer loyalty.
  4. Environmental Considerations: Sustainable packaging is a growing concern for consumers. Custom inserts made from recyclable and biodegradable materials can help reduce your environmental impact and resonate with eco-conscious customers.

While custom inserts offer numerous benefits, it's important to consider some potential drawbacks as well.

Potential Disadvantages

  1. Custom Design Complexity: Creating custom inserts requires time and effort to ensure the right fit and design. Unlike stock packaging, custom inserts are tailored to specific products, which may lead to longer production times.
  2. Logistical Challenges: If you sell a wide range of products, designing custom inserts for each item can be a logistical challenge. It may require additional resources and coordination to ensure that every product has an appropriate insert.
  3. Higher Costs: Custom inserts can be more expensive than alternative void-fill options. Consider your budget and weigh the benefits against the additional cost before deciding on custom inserts.

While these drawbacks should be taken into account, the potential benefits of custom inserts often outweigh the challenges. With careful planning and consideration, custom inserts can be a valuable addition to your packaging strategy.


Custom packaging inserts offer a range of benefits, from robust product protection to enhanced presentation and brand recognition. By carefully selecting the right material, designing the perfect insert, and incorporating branding elements, you can create a packaging experience that delights your customers and sets your brand apart. Consider the different types of custom inserts, evaluate the materials, and explore design options that align with your brand values. With custom inserts, you can elevate your packaging and create a memorable unboxing experience that leaves a lasting impression.

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