Packaging Insert Ideas for a Better Unboxing
Packaging inserts are the part of the box your customer actually touches first.
Here is how to pick the right ones, and what to leave out.
By PLC Print
Packaging Inserts Side by Side
The most common inserts, and what each one does.
| Insert | What it does | Protection | Good for |
|---|---|---|---|
| Paperboard tray | Holds items in place | Medium | Sets, kits, cosmetics |
| Corrugated divider | Keeps items apart | Medium to high | Bottles, multi-packs |
| Foam insert | Locks fragile items in a cut-out | High | Glass, electronics, gift sets |
| Molded pulp | Cradles the product, recyclable | Medium to high | Eco brands, bottles, candles |
| Printed card | Says thank you, explains, invites a reorder | None | Every box |
Hold the Product in Place
A product that slides around in the box arrives scuffed, or worse. Custom box inserts fix that by giving each item its own spot. Paperboard trays and corrugated dividers are light, print well and recycle easily. Foam inserts for boxes are the strongest option for glass and anything that breaks.
The insert has to be cut to the real product, so it pays to size it from finished samples, not from a spec sheet. With our custom packaging service, we handle the box and insert together so they fit.
Good for
- Paperboard for sets and kits.
- Foam for glass and fragile gifts.
Watch out
- Foam is harder to recycle at the curb.
- If your brand talks about sustainability, look at molded pulp or paperboard first.
Make the Box Easy to Open
This is the part most brands skip, and customers notice. A 2026 survey of 1,000 U.S. adults who work in small businesses found that 78.8% have needed a tool to open packaging at least a few times a month, and 48.1% have stopped buying a product because of its packaging.
Simple fixes help. A tear strip on the mailer. A pull tab or ribbon on the tray so the product lifts out. A tuck flap instead of a box taped shut on every side.
Good for
- Tear strips on mailers and ribbon pulls on trays.
- Tuck flaps on retail boxes.
Watch out
- Plastic clamshells and heavy tape protect the product.
- They also frustrate the person opening it.
Say Something With a Printed Card
A printed card is the cheapest way to improve the unboxing experience. Use it to say thank you, explain how to use the product, or put a QR code for reorders right where the customer is looking.
Keep it to a single card. A stack of flyers feels like junk mail, and the same survey lists wasteful packaging among the things that frustrate buyers.
Good for
- Thank-you notes and care instructions.
- A QR code for reorders.
Watch out
- Skip printed discount codes that expire fast.
- The card often sits on a desk for weeks.
Inserts for a Three-Bottle Skincare Set
Say a skincare brand ships a set of three glass bottles to online customers. Here is how we would put it together.
Paperboard tray
Die-cut holes, so the bottles stand upright and stay apart.
Tear strip and ribbon
A mailer with a tear strip and a ribbon pull on the tray.
Printed card
A thank-you and a QR code for reorders.
Plastic clamshell
It protects the bottles but nobody enjoys opening it.
The simple rule: hold it snug, make it easy to open, and say thanks.
Packaging Inserts FAQ
What are packaging inserts?
Packaging inserts are anything that goes inside the box besides the product: trays, dividers, foam, pulp, and printed cards.
Foam or paperboard: which is better?
Foam protects best for glass and fragile items. Paperboard is lighter, cheaper to ship and easier to recycle. Many sets work fine with a well-fitted paperboard tray.
Do inserts add shipping cost?
A little weight, but a snug insert often lets you use a smaller box, which can save more than the insert costs.
What should a packaging insert card say?
Keep it short: thank you, how to use the product, and a way to reorder or follow the brand.
Can I see samples before I order?
Yes. We have stock samples of insert materials, and we can make custom samples so you can test the fit with your product.
Final Thoughts
Good packaging inserts do three jobs: hold the product in place, make the box easy to open, and say something worth reading. Get those right and the box feels like part of the product. PLC Print takes care of your box, inserts and printed cards start to finish.
A snug tray or foam insert, sized to the real product.
Tear strips and pull tabs, not tape.
A single printed card, not a stack of flyers.
Want a Box People Enjoy Opening?
Tell PLC Print what you ship and we will help you pick the right inserts.