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Phone: (760) 471-1000

Toll Free: 1-888-776-8000

Fax: (760) 471-1099

Boxes and displays are MADE IN U.S.A.

The Best Internal Packaging Materials When Shipping

Custom foam insert
When designing shipping boxes, there is usually some space allowance given between the item and the interior walls of the box. This space is not usually big, particularly with custom boxes. But it is necessary to provide space for packaging materials that will help provide added protection. These materials help to absorb shock and prevent the contents from shifting around. This padding is also important in case the box is perforated. There is less risk the product will be damaged. Here are some of the best options in interior packaging.

Foam Inserts

This is probably the most stable option for products. The foam material is typically quite rigid yet lightweight, providing an effective way for products to remain stable and insulated within a box. They are a good option for shipping & packing materials for expensive commodities like electronics whose mishandling can lead to internal damage. The inserts tend to be thick, ensuring any damage to the box does not get to the contents within. Cardboard inserts can be used for less expensive and smaller lightweight items.

Bubble Wrap

Bubble wrap offers a great cushioning effect that is ideal for protecting fragile items. It is made up of air pockets or bubbles that ably absorb shocks and vibrations, preventing the contents of the box from becoming damaged. It is one of the most lightweight packaging materials, meaning little if any added cost of shipping. There are several variations of bubble wrap including those that come with different sized “bubbles” and self-adhesive options.


Different kinds of paper can be crumpled up and stuffed around objects in a box. They can also be wrapped around the items. This helps to stabilize them and absorb any shocks during transport. If several items are being kept in the same box, this also helps to ensure they do not bang into each other causing breakage. You can use just about any paper with newspaper and brown paper often being chosen.

Packing Peanuts

Traditionally made from polystyrene, these packaging materials are great for filling up awkward spaces around products that are being boxed. When filled in a box, they provide a soft barrier around the product that can absorb shocks, shaking, jostling, and other rough handling. They can be found in a variety of shapes and sizes. There are also recyclable and biodegradable varieties that are safe for the environment. They have also been made non-toxic due to the frequent occurrence of children eating them.

How Do Custom Foam Insert Pieces Help in Packaging?

Custom Foam Insert
You may be experiencing excess amounts of damages for your items, products, equipment or components when shipping or transporting them. It may also be that your expensive tools are getting lost on-site or you need a professional way you can present your brand or samples in a sales presentation to help in boosting orders. Or you could be seeking brand differentiation in a retail market that is saturated. All these are possible situations where you may need to use custom foam inserts. Regardless of the industry, application, or budget, using a custom foam insert is able to help you meet these goals and it can have a direct positive impact not only on operations but also on the profitability of your retail business.

So how can foam inserts help your business?

Extra Layer of Packaging Protection

When you use a custom made foam inserts, they provide a cushioning for high-end items or high ticket items. When you place the inserts, they reduce the chances of damage and the cost of damage during transit. Your products arrive in good form and you don’t have to worry about breakages. For example, you can cushion items like smartphones, their accessories, TV sets, radios, appliances, and other high-end products.

Quality Finishes for Enhanced Sales

The inserts can have high-quality finishes to help enhance brand awareness and increase sales of high-end and luxury consumer products. Imagine how it would feel when you open a package and you find that it has a unique insert design with vibrant colors and probably some branding message on it? It feels more connected with the product or brand. The customer has the feeling that the product seller or the retail store understands the touchpoints to engage with their clients. It’s not typical for many brands to do this, however, when you do it, it distances you from the crowd. The customers you serve with the products will be proud to buy them from you because they are finding unique features in it including the packaging.

“Shadow Board” To Prevent Loss of Product or Item

Using foam dividers and inserts helps provide a board where you place the designated items or accessories. For example, if it’s a smartphone, it may have a board with different cuts or designs where the phone goes, the charger is placed, and the pen is put. In the event that the box accidentally opens, you can know if there is something missing. The shadow board product placement foam helps prevent loss of accessories and items in packaging. It also helps in tool control where you can see which tools haven’t been placed in the box before leaving the site.

Whether it’s convoluted foam or customized inserts, you need to ensure that they are designed to meet your packaging needs. It is a bit expensive to design and produce them, however, when you got them, you can use them for a lifetime. Also, the lead time for producing the customized inserts is more compared to the pick and pluck foam inserts. However, it is worth the wait because you get pieces that will last for longer and you reuse them over and over again for your shipping needs.

Besides, you will ensure that you don’t get complaints about defective products while on transit because the packaging space has been optimized with the use of inserts. Retail businesses, as well as manufacturing companies, can use these accessories for branding their products and adding value to the items they ship. The design options for these pieces of inserts and dividers are many, you just have to work creatively with the packaging designers.