Corrugated insert
E-flute200 minimum · 10 to 12 business daysA corrugated insert is a die-cut piece of E-flute or B-flute board that holds a product still inside a shipping box, as a cradle, a divider, a pad or a folded frame. We produce them to fit our mailers or any carton, from 200 units in 10 to 12 business days after proof. Most are cut for 8 by 6 by 3 or 10 by 8 by 4 inch mailers.
When to choose it, and when not to
Choose a corrugated insert when the box is going through a carrier and the product must not move. A candle in a mailer, six jars in a shipping box, a bottle that would otherwise roll. A die-cut E-flute cradle costs less than a single damage claim and weighs almost nothing, which keeps the parcel inside the same rate band. It suits anything from 1 to 15 pounds that has to arrive the way it left.
Choose a die-cut paperboard insert when the box is a carton or rigid box that does not ship on its own, because corrugated looks industrial where paperboard looks finished. Choose a foam insert for glass, electronics or anything that cannot take a knock at all, since E-flute cushions a rattle but not a drop from a van.
Specifications
| Board | E-flute, 32 ECT, or B-flute for heavy items, kraft or white liner |
|---|---|
| Plain, or one color flexo on the top face | |
| Finish | Natural kraft or white, uncoated |
| Closure | None, friction fit or tab-locked into the box |
| Insert | Cradle, divider set, top and bottom pad, or folded frame |
| Load | Rated for items up to 8 pounds in E-flute, 15 in B-flute |
| Minimum | 200 units |
| Lead time | 10 to 12 business days after proof |
| Ships | Flat, in bundles of 50 |
| Sizes we run | cut to fit a 6 x 6 x 4 in mailer cut to fit a 8 x 6 x 3 in mailer cut to fit a 10 x 8 x 4 in mailer cut to fit a 12 x 9 x 4 in mailer any size from 4 x 4 to 18 x 14 in footprint |
Materials that suit it
Questions people ask
Which style of insert do I need?
A cradle for one or two items that must stay upright, such as jars or bottles. A divider set for four to twelve items of the same size. A top and bottom pad for something flat that needs a crush layer, such as a framed print. A folded frame for a product that should float in the box with a gap on every side.
E-flute or B-flute?
E-flute is 0.06 in thick and is right for anything up to about 8 pounds. It folds cleanly and looks tidy. B-flute is 1/8 in, stiffer, and better for bottles, ceramics and cases of six. It does not fold as neatly, so we use it for flat pads and dividers rather than folded cradles.
Can it be printed?
One color flexo on the top face, yes, and it is a cheap way to add a color block or a thank you line to a plain kraft mailer. Full color on corrugated is possible but the flute shows through a large solid, so for a photographic insert use paperboard over the corrugated.
How much does an insert add to the parcel weight?
An E-flute cradle for a 10 by 8 mailer weighs about 1.5 ounces. A B-flute six-bottle divider set is about 5 ounces. Neither usually moves a parcel into the next carrier band. We list the insert weight on the proof so you can check against your rate card.
Will you test the fit before the run?
Yes. Send the product or its exact dimensions and we have a sample insert cut and fitted to the box. On a run of 200 we usually do this with your first proof. For fragile items we recommend you drop-test a filled box from about 3 feet before approving, and we will tell you what to look for.
How is a corrugated insert different from a die-cut paperboard insert?
The corrugated insert carries weight: E-flute at 32 ECT for items up to about 8 pounds, B-flute up to about 15, as a cradle, divider, pad or folded frame inside a shipping box. The die-cut paperboard insert is thinner 18 to 24pt SBS that prints cleanly and suits light products shown in a carton or mailer. Both start at 200 units in 10 to 12 business days after proof. Bottles, jars and heavy sets in a shipper suit corrugated.
Similar styles
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Ready to price your corrugated insert?
Send the size and quantity for a quote and a dieline, usually within one business day. Your digital proof follows, usually within one business day of your artwork. Design help and the Swatch Book of materials are free.