Custom Corrugated Box Dividers
Custom corrugated dividers cut to your box and the items it carries, from 100 sets. Send the internal box size and the item count; the cell layout, the dieline and the price come back the same working day.
The cheapest way to stop twelve bottles arriving as eleven
- Board
- E, B or BC flute; kraft or white liner
- Builds
- Slotted cross partitions, die-cut inserts, layer and bottom pads
- Layouts
- Any grid from 2×1 upward; cells sized to the item plus clearance
Get a price for Corrugated Box Dividers
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
Slotted partitions: the one that assembles in a second
Strips of corrugated slotted halfway through, crossed into a grid. No glue, ships flat, and drops into the box in one motion. Two by two, three by four, six by six — the layout follows the item count and the box. The cell size is set to the item plus a little room, so a bottle sits in its cell without rattling and without needing to be forced.
The partitions are cut to the box, so where the box is not decided yet the shipper and the cells are sized together.
| Light items, up to 300 g each | E flute strips |
|---|---|
| Bottles, jars, candles | B flute strips, full box depth |
| Heavy or glass items in transit | B or BC flute, with a bottom pad |
Die-cut inserts for things that are not rectangular
Where the item is a shape — a bottle with a neck, a tool, a round tin — a die-cut insert holds it at the points that matter. A single board with cut-outs for necks, a folded platform that lifts the item off the floor, or a two-layer insert that locates the base and the shoulder separately. The cutting die is made once and kept, so the second run skips the tooling.
Depth, pads and the wall the divider braces
- Cut the partition to the full internal depth of the box, so it braces the lid as well as the sides.
- Add a bottom pad where the items are heavier than the board — a flat sheet spreads the load off the box floor.
- A top pad under the lid stops a partition printing through and protects against a blade at unboxing.
- Leave 2–3 mm clearance around the item in each cell; a tight cell is slow to fill and can scuff labels.
Dividers make the box smaller, not larger
Counter-intuitive but reliable: a box with a divider can be sized close to the items, because nothing needs room to be wrapped or padded. Without one, the same items need void fill and a larger box, which costs more at the carrier every time. Our inserts that hold products in place cover the foam and molded-pulp options for when corrugated is not enough.
Plain, or printed with the cell contents
Most dividers are plain kraft and never seen by a customer. Where they are seen — a gift set, a tasting box — a white liner and one color of print on the top edge or the cells turns the insert into part of the presentation, for very little over plain.
Send us the box size and the item dimensions, and we lay out the cells. If the box does not exist yet, we size both together.
Corrugated Box Dividers — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Board
- E, B or BC flute; kraft or white liner
- Builds
- Slotted cross partitions, die-cut inserts, layer and bottom pads
- Layouts
- Any grid from 2×1 upward; cells sized to the item plus clearance
- Sizing
- Cut to the internal box dimensions you send, full depth as standard
- Plain kraft standard; one color on white liner for visible inserts
- Supply
- Flat; slotted partitions assemble by hand without glue
- Minimum
- 100 sets
On every job
- Print process
- Flexo in one to four colors straight onto the liner; litho-lamination where the box needs full color or a photograph.
- Color
- Flat colors on kraft. Full color needs a white top liner or a laminated sheet, because brown shifts every color warm.
- Tolerance
- Cutting plus or minus 1.5 mm. The flute compresses, so corrugated runs wider than folding board.
- Tooling
- No die on a regular slotted box, which is cut on a slotter. Die-cut mailers and trays need one, made once and kept.
- Food contact
- Food-grade liners and a vented build where the box carries hot food.
- Sustainability
- High recycled content through liners and flute as standard, and the box recycles whole if it is sealed with paper tape.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build corrugated box dividers on
Corrugated is a fluted sheet glued between two liners, and the flute decides nearly everything: how it prints, how it dents, how high it stacks. These are the grades we run.
E flute
About 1.5 mm. Prints well and folds crisply; dents under a stack. Retail boxes, mailers and light shippers.
1.5 mm, single wallB flute
About 3 mm. The working default for parcels — takes print reasonably and stacks reasonably. Most shipping boxes are B.
3 mm, single wallC flute
About 4 mm. More cushioning than B, slightly less stacking strength per weight. Common on grocery and produce cases.
4 mm, single wallBC double wall
B and C glued together, about 7 mm. Heavy or fragile goods, pallet stacking, anything over roughly 15 kg.
7 mm, double wallKraft liner
Brown, strong, absorbent. One or two flat colors flexo print well on it; photographs drink into the brown and go muddy.
Outer and inner linerWhite top liner
A bleached outer liner for full-color print on corrugated. Costs more and marks more easily than kraft.
Outer liner onlyRecycled-content corrugated
High post-consumer fiber through liners and flute. The default for shippers; a slightly greyer brown and no loss of strength at grade.
All flutesCoated and water-resistant
A coating or a wax-free barrier liner for damp stores and cold chains. Check the recycling stream before printing a claim on it.
B and C fluteNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
Corrugated takes fewer finishes than folding board, and the ones it takes it takes well.
Flexo on kraft
One or two flat colors straight onto brown. Cheap, fast, honest.
Litho-lamination
An offset sheet glued to the flute: full color and photographs on a shipper.
Aqueous varnish
Scuff resistance with no film, so the box still recycles whole.
White top print
Full color flexo on a bleached liner; brighter, and it marks more easily.
Inside print
A second pass on the inner liner — the panel a customer sees first.
Printed tape seal
The brand applied at the last moment, on paper tape that recycles with the box.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing a corrugated box against the carrier, not the catalog: corrugated box dividers
Corrugated is cut to your internal size, so the box goes round the product rather than the product going into a stock size. That is where the money is: a box 20 mm smaller each way is often a whole postage band cheaper.
- Internal dimensions
- Length, width and depth of the space you need. Board thickness is added outside that, and the flute is thicker than people expect.
- Clearance and void fill
- 5–10 mm a side for a rigid product. Size it properly and you need no void fill at all, which is cheaper and better received.
- Stacking
- Tell us how high the boxes stack on a pallet or a shelf. Edge crush grade is specified from that, not guessed.
- Weight
- The contents weight sets the flute and the liner grade. Over about 15 kg we move to double wall.
- Score allowance
- Corrugated needs more room at the folds than boxboard. The dieline accounts for it; a box drawn from flat dimensions comes out tight.
- Cutting tolerance
- Plus or minus 1.5 mm on corrugated, wider than folding board because the flute compresses.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
Interactive · five steps · no sign-up
Build your Corrugated Box Dividers in 3D
Pick a shape, type a size, choose a board and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about corrugated box dividers? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
How do I order dividers for a box I already have?
Send the internal length, width and depth of the box and the size and count of the items. We lay out the cells and send a dieline to check before cutting.
Can you make the box and the divider together?
Yes, and it is the better way round, because the box can then be sized to the divider rather than the divider squeezed into the box.
Do the partitions come assembled?
No. Slotted partitions ship flat as strips and cross together by hand in a second or two. Die-cut inserts ship flat and fold if they need to.
Which flute should the divider be?
E flute for light items, B flute for bottles and jars, BC where the items are heavy or glass. It is usually the same flute as the box or one grade lighter.
How much room should each cell have?
Two to three millimeters around the item. Enough that it drops in without force, not so much that it rattles.
Can you cut a divider for round or odd-shaped items?
Yes. A die-cut insert with shaped cut-outs holds bottles at the neck, tins by the rim, or a tool at two points. The die is made once and kept.
Do I need a bottom pad?
If the items are heavy or glass, yes. A flat pad spreads the load off the box floor and protects against a drop on the corner.
What is the minimum order?
100 sets.
Can dividers be printed?
Yes, though most are plain. For a gift or tasting box a white liner with one color of print on the visible edges is inexpensive and changes the feel of the pack.
Are they recyclable?
Plain corrugated dividers recycle with the box. A printed white liner does not change that.
Will a divider stop bottles breaking?
It stops them touching each other, which is how most bottle breakage starts. For drops, pair it with a bottom pad and the right flute in the outer box.
Do you send a dieline?
With the quote, showing the cell layout at true size, so you can check the count and the fit before anything is cut.
How fast can I get them?
The date comes with the quote once we have seen the spec. Slotted partitions need no tooling, so they are among the quickest things we make.
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