Converting & Assembly
Packaging Inserts
Die-cut paperboard or molded structures that hold products securely inside the box.
What it is
Packaging inserts are the interior structures that cradle products during transit and present them beautifully at unboxing. They range from die-cut paperboard trays and dividers to molded pulp forms, and are tailored to the product shape. ZKPACKS designs inserts for rigid boxes, cartons and gift sets with the product dimensions in mind.
How it looks
Tidy, organized product presentation with layered unboxing.
How it feels
Structured interior that holds each item firmly in place.
Verified media pending
A media slot—not a fabricated factory image.
Add ZKPACKS sample close-ups, before/after comparisons or verified production media when source and process attribution are confirmed.
Suitable materials
- SBS paperboard
- CCNB
- Molded paper pulp
- EVA-free paperboard
- Rigid board
Suitable packaging types
- Rigid gift boxes
- Cosmetic gift sets
- Jewelry boxes
- Folding cartons
Recommended combinations
- Die-cut inserts with rigid boxes
- Printed inserts with folding cartons
- V-grooved insert trays with luxury gift boxes
Artwork requirements
- Accurate product dimensions for the insert layout
- Dieline with folds and slots defined
- Printed insert artwork with bleed where visible
Limitations
- — Custom inserts need tooling for die-cut or molded forms
- — Deep, complex cavities increase cost
- — Insert design must account for product tolerances
Production risks
- — Poor fit if product dimensions change after design
- — Tearing at tight folds in thin board inserts
- — Material dust or loose fibers on molded forms
Sustainability considerations
Paperboard and molded pulp inserts are paper-based and may be recyclable subject to material specification, local collection infrastructure and any coating or lamination used.
FAQ
Buying questions
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