Designing Foam and Corrugated Hybrid Inserts
Foam-in-corrugated hybrid inserts combine the cushioning properties of foam with the structural rigidity of corrugated board, creating a packaging solution that is both protective and adaptable. This design approach is particularly useful in industries where precision fit and shock absorption are critical, such as electronics, medical devices, and high-value industrial components.
Why Combine Foam and Corrugated?
Corrugated offers structural stability, vertical stacking strength, and a printable surface for branding or instructions. Foam provides vibration dampening, energy absorption during impact, and surface protection against scratches or abrasions. When integrated, these materials address a broader range of performance requirements than either could alone.
Material Selection
The choice of foam type—such as polyethylene (PE), polyurethane (PU), or expanded polystyrene (EPS)—should be driven by product fragility, weight, and storage conditions. PE foam, for example, excels in repeated compression recovery, making it suitable for reusable inserts. Corrugated board grades (e.g., single-wall B-flute vs. double-wall BC-flute) must be matched to anticipated stacking loads and compression requirements.
Bonding Methods and Compatibility
Adhesive selection is critical. Water-based adhesives can warp corrugated under high humidity, while hot-melt options may degrade certain foam chemistries. Mechanical retention methods, such as die-cut lock tabs or slotted cavities, can reduce adhesive usage and improve recyclability.
Engineering Fit and Tolerance Control
Foam compression should be engineered to 10–30% deflection under typical product weight to balance retention and ease of removal. Corrugated cutouts must account for foam expansion and any dimensional variation due to manufacturing tolerances. Overly tight fits can cause stress concentrations, while loose fits reduce protection efficiency.
Shock and Vibration Performance
ASTM D1596 testing can determine the foam’s cushioning curve, ensuring the hybrid insert meets drop-test performance requirements. Corrugated structure should be verified under ASTM D642 compression testing to confirm stacking safety in transit and storage.
Sustainability Considerations
Designing with minimal adhesive, using water-based inks for print, and specifying recyclable PE foams can increase end-of-life recyclability. An emerging approach is designing separable components so the foam and corrugated can be easily disassembled for proper recycling streams.
References
American Society for Testing and Materials. (2019). ASTM D1596-14: Standard Test Method for Dynamic Shock Cushioning Characteristics of Packaging Material. https://doi.org/10.1520/D1596-14
American Society for Testing and Materials. (2015). ASTM D642-15: Standard Test Method for Determining Compressive Resistance of Shipping Containers. https://doi.org/10.1520/D0642-15
Soroka, W. (2016). Fundamentals of Packaging Technology (5th ed.). Institute of Packaging Professionals.
Kistler, S. F., & Schweizer, P. M. (Eds.). (2013). Liquid Film Coating: Scientific Principles and Their Technological Implications. Springer. https://doi.org/10.1007/978-94-011-4942-0
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Corrugated boxes are a packaging mainstay, known for their durability, affordability, and eco-friendliness. Yet, when it comes to securing delicate or valuable items during transit, the use of inserts becomes indispensable. In this guide, we’ll explore the world of packaging inserts, focusing on the most popular types for corrugated boxes. Discover their styles, properties, benefits, and applications, ensuring your precious cargo reaches its destination unscathed. Whether it’s electronics, glassware, or other valuable items, let’s navigate the realm of packaging inserts to safeguard your shipments effectively. Foam Corrugated Plastic Pulp Chipboard Fabric Foam Inserts Foam inserts serve as a dependable choice for safeguarding delicate items, including electronics, glassware, and medical equipment. These inserts can be tailored to match products precisely, effectively preventing any movement during shipping. Additionally, foam inserts are known for their lightweight nature, recyclability, and environmentally friendly characteristics. Corrugated Inserts Corrugated inserts share the same sturdy and cost-effective qualities as the corrugated boxes themselves. Available in various styles, such as dividers, partitions, and trays, these inserts offer structural support, organization, and protection to your items. This makes them an ideal choice for numerous applications. Plastic Inserts Plastic inserts are designed to combat moisture and are particularly suitable for products susceptible to moisture damage. Crafted from a range of plastic materials like PVC, PET, and polypropylene, these inserts can be customized in various shapes and sizes to snugly accommodate specific products. Notably, they are both easy to clean and reusable, ensuring long-term cost-effectiveness. Pulp Inserts Eco-conscious consumers often prefer pulp inserts, which are crafted from recycled materials. These inserts are perfect for safeguarding fragile items such as glassware, ceramics, and electronics. They are created by mixing paper and water, molding them into the desired shape with a special machine. Moreover, pulp inserts can be customized for specific products and are biodegradable, aligning with sustainable practices. Chipboard Inserts Chipboard inserts represent an eco-friendly choice made from recycled paper. These inserts are available in various thicknesses and can be customized to protect items prone to bending or warping during transportation. Their versatility makes them a preferred option for many applications. Fabric Inserts Fabric inserts are a great choice for safeguarding products sensitive to scratches, scuffs, or abrasions. Crafted from various fabric materials, such as cotton, velvet, and microfiber, they offer customizable protection. Furthermore, these inserts are reusable, which not only makes them cost-effective in the long run but also aligns with environmentally friendly practices. For all your packaging insert needs for corrugated boxes, partner with Brown Packaging today to get started. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Packaging Inserts Facebook Twitter LinkedIn Pinterest Relevant Posts
Understanding One-Piece FOL and Three-Piece Bike Shipping Boxes Choosing the right box style is essential when shipping bicycles—especially for brands, manufacturers, and distributors focused on protection, cost efficiency, and streamlined logistics. Two commonly used formats are the Full Overlap (FOL) one-piece box and the three-piece bike box. Each has distinct structural advantages depending on the bike type, destination, and handling environment. What Is a Full Overlap (FOL) Bike Shipping Box? A Full Overlap (FOL) box is a one-piece corrugated shipping box where the top and bottom flaps fully overlap each other when closed. This design is especially valuable for long or narrow products like bikes. Benefits include: Strong Compression Resistance – The full overlapping flaps provide double-layered protection on the top and bottom panels. Simplified Handling and Assembly – Arrives as a single piece and requires only folding and taping, making it efficient for production lines. Cost-Effective for Standard Shipments – Fewer components and straightforward manufacturing keep material and labor costs low. Ideal for Flat-Pack or Dismantled Bikes – Works well for partially disassembled bikes with adequate internal protection. What Is a Three-Piece Bike Shipping Box? A three-piece box includes a base, a lid, and a center sleeve that wraps vertically around the bike. This structure is often used for premium or specialty bikes that require enhanced protection. Key advantages: Superior Durability and Protection – Multiple corrugated layers absorb impact, stacking pressure, and long-haul wear. Height Flexibility – The sleeve allows the box height to adjust to fit different bike sizes or accessory configurations. Excellent for Fragile or High-Value Bikes – Ideal for electric bikes, luxury models, or international shipments where added security is crucial. Enhanced Brand Presentation – The modular design offers more surface area and structural options for branded unboxing experiences. FOL vs. Three-Piece: Key Differences Feature FOL (One-Piece) Box Three-Piece Box Components Single box with overlapping flaps Base + Lid + Sleeve Protection Level Moderate – suitable for standard use High – layered protection for fragile items Assembly Fast, efficient Requires more steps and alignment Material Usage Less – more cost-efficient More – adds reinforcement and dimensional control Best For Flat-packed bikes, short-distance High-end bikes, eBikes, or global distribution Which Bike Shipping Box Is Right for Your Business? The decision depends on your bike model, packaging workflow, and shipping conditions: Use an FOL box when speed, simplicity, and cost efficiency are priorities—especially for standard bikes with proper internal bracing. Choose a three-piece box when your product demands premium protection, flexible sizing, or is headed to distant or high-risk destinations. Custom Structural Packaging for Bikes Both FOL and three-piece bike boxes can be optimized with: Die-cut inserts or partitions for immobilizing frames and wheels Branded folding cartons for manuals, tools, or accessories Foam, corrugated, or molded trays for secure internal protection Print-ready panels for logos, instructions, or compliance labels Looking for a purpose-built solution? Brown Packaging can help you engineer a custom structure that ensures protection, efficiency, and brand value. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Bike Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
In the world of packaging, there’s a constant pursuit of innovation and improvement to ensure products are not only securely packaged but also easy to access. One such advancement in packaging technology is the incorporation of cherry locks in roll end tuck top (RETT) boxes. In this blog, we will delve into the intricacies of cherry locks, exploring their design, features, benefits, and the scenarios where they prove to be an invaluable addition to RETT boxes. Understanding Cherry Locks Cherry locks, also known as snap locks or friction locks, are a locking mechanism employed in packaging to secure the top flaps of boxes without the need for additional adhesives or tape. These locks are specifically designed to offer a secure closure while allowing for effortless and repeated opening, making them ideal for applications where ease of access is crucial. Here’s a closer look at their design and features: Benefits of Cherry Locks Cherry locks offer several advantages, making them a valuable addition to RETT boxes: Enhanced Security: Cherry locks provide a secure closure that prevents accidental opening during transit while deterring tampering or unauthorized access. Easy Access: The user-friendly design of cherry locks allows for quick and effortless opening, making them ideal for products that need to be accessed frequently, such as retail items or subscription boxes. Sustainability: Cherry locks contribute to sustainability efforts as they reduce the reliance on single-use adhesives and tapes, promoting eco-friendly packaging practices. These boxes can also be reused and repurposed. Cost Savings: While cherry locks may initially seem like a slightly higher investment, their reusability ultimately leads to cost savings by eliminating the need for additional sealing materials. Cherry Locks in Roll End Tuck Top Boxes Roll end tuck top boxes, with their inherent durability and versatility, are a perfect pairing for cherry locks. These boxes are constructed to provide a secure enclosure while allowing for easy customization and branding. When cherry locks are integrated into RETT boxes, they bring an added layer of security and convenience to the packaging solution. Scenarios for Using Cherry Locks in RETT Boxes Cherry locks are a versatile locking mechanism that can be employed in various industries and applications: Retail Packaging: RETT boxes with cherry locks are an excellent choice for retail packaging, ensuring that products remain secure on the shelves while allowing customers to open and inspect them easily. E-commerce: For e-commerce businesses, cherry locks enhance the security of shipped items while offering recipients a hassle-free unboxing experience. Subscription Boxes: Subscription box services benefit from cherry locks as they combine security with the convenience of repeated opening for subscribers. Electronics and Gadgets: Sensitive electronics and gadgets can be securely packaged with cherry locks, ensuring the contents are protected during shipping and readily accessible to users. Conclusion Cherry locks in roll end tuck top boxes represent a significant innovation in packaging design, offering the perfect balance between security and ease of access. Understanding the design, features, benefits, and potential applications of cherry locks can help businesses make informed choices when selecting packaging solutions. Whether you are in retail, e-commerce, or any other industry, the integration of cherry locks into RETT boxes can enhance your packaging strategy, providing a secure and user-friendly experience for both businesses and customers alike. If you are interested in roll end tuck top boxes with cherry locks, then partner with Brown Packaging today to get started. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Roll End Tuck Top Facebook Twitter LinkedIn Pinterest Relevant Posts