Short answer
Fragile packs need three layers: a surface wrap to stop scratching, a cushioning layer to absorb shock, and an outer box strong enough that nothing reaches the product. Double boxing with 50 mm of cushioning between the two boxes is the reliable answer for high-value fragile goods.
Build it in layers
- Layer 1: tissue, foam sheet or honeycomb wrap against the finish.
- Layer 2: bubble, foam profile or a die cut corrugated insert to hold the item still.
- Layer 3: a double wall outer with at least 50 mm of clearance filled with cushioning.
- Corners and edges take the worst of every drop, so pad them first and most.
Inserts beat loose fill
Loose fill settles in transit and leaves the product resting on the box wall by the time it arrives. A die cut fitment made from the same board as the box holds the product in position for the whole journey and often costs less than the fill it replaces.
Prove it before you scale
We make free samples with fitments so you can drop test with your own product. If it breaks in our sample, that is a much cheaper lesson than finding out through customer returns. Gifting a fragile item alongside a balloon? Shipping framed art or mirrors? Our picture frame boxes page covers corner protection and board grades for glazed pieces. See our balloon packaging for tall bubble balloon boxes, hamper trays and window lantern styles made to measure.
Frequently asked questions
- Should I double box fragile items?
- For high-value or genuinely fragile goods, yes. Aim for around 50 mm of cushioning between the inner and outer box.
- Can you make foam or cardboard inserts?
- Yes, we make die cut corrugated fitments in-house and supply foam profiles and end caps.
- Do fragile labels help?
- They help a little. Correct construction helps far more, so treat labels as a supplement, not a strategy.
Think your packaging is bigger than it needs to be?
Send us your product dimensions and we’ll come back with a right-sized option. There is no minimum on stock lines, and bespoke corrugated runs can start from as little as one, but we will advise the most cost efficient run rate depending on size and board grade.
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