Protective and assembled packaging: partitions, inserts and cushioning for fragile products
Assembled packaging is a system in which the outer box works with multiple inner components to hold the product in place, separate items and absorb impact throughout shipping. In the FEFCO system, these components are classified as series 0900 (interior fitments) and are made from the same corrugated board as the outer box.
Because every component is made from the same corrugated board as the outer box, the entire pack can be disposed of together without sorting and recycled with other paper. This adds no waste-handling burden for your customers, unlike foam and plastic cushioning, which require separate disposal.
Box styles in this group
Partition / Divider
Slotted corrugated strips that interlock to form a grid of cells, preventing items from touching one another. This is the most frequently ordered component in this group, used for glass bottles, cosmetics, ceramics and electronic components.
Pad
A flat sheet placed on the bottom of the box, between product layers, or on top before closing. It adds vertical impact protection and helps distribute compression when boxes are stacked.
Liner
A corrugated sheet folded into a U or O shape to line the inner walls of the box. It adds a further wall layer and increases the compression strength (BCT) of the existing box. Used when a product becomes heavier but the specification of the outer box is to remain unchanged.
Cushioning / Insert / Fitment
Components cut and folded to the shape of a specific product, holding it in place away from the box walls so that impact is absorbed by the board rather than the product. Designed around the actual product for every order, and essential to electronics and medical device packaging.
Wrap Sheet / Surround Board
A corrugated sheet that surrounds the product on all four sides. The product is placed on a pad or tray, the wrap sheet is placed around it, and a top layer closes the pack. Suited to large, heavy products, and can be made extra thick for high loads. It is also used around the outside of a box for added strength, or around a large product without a box.
Corner Protector / Edge Protector
Corrugated board folded into an L or U profile to cover the corners and edges of a product, protecting them from strapping pressure and impact during handling. Commonly used with pallets and furniture.
Tray and Lid Set
A rigid base tray with a lid and an inner fitment. Lifting the lid reveals the complete set at once, suited to premium products where the unboxing is part of the brand experience.
Selecting protective packaging
Designed around your actual product
This group has no standard designs. Every component is designed to the actual dimensions of the product, as a difference of a few millimeters can significantly affect the level of protection.1. The product
- The most fragile areas: corners, edges, surfaces or protruding parts.
- Weight per item and items per box, which determine the compression the partitions must withstand.
- Distance and number of handling stages. The more often the box is handled, the more cushioning it requires.
- Number of stacked layers in storage, and how many times the box will be reused.
- General partitions and pads: KK grade, B flute.
- High compression or repeated reuse: KA grade.