Glass fails in transit for three reasons: it hits the inside of the box, it hits another piece of glass, or the box itself fails and the contents take the impact directly. Every technique below addresses one of those three. Work through them in order rather than picking one.
Stop the glass touching the walls
The working rule taught throughout the shipping trade is about 2 in of cushioning between the product and the outer box on every one of the six faces. Base and top matter as much as the sides, because boxes get dropped on their corners and ends more often than on their faces. Loose fill, paper, foam, moulded pulp and air pillows all work, and what matters is that the gap is filled consistently rather than which material fills it. A pack that has 2 in on four sides and nothing under the base will fail at the base.
Stop the glass touching other glass
Two bottles that knock together will break even inside a well cushioned box. A full cell wall between every unit is the fix, and there are three usual formats.
| Format | Best for | Notes |
|---|---|---|
| Corrugated partitions | Bottles, jars, multi packs | Paper only, ships flat, easy to reorder |
| Moulded pulp fitment | Uniform shapes in volume | Holds the neck and base, excellent retention |
| Die cut board fitment | Irregular or mixed shapes | Cut to the product, good for sets |
The partition options are on the partition boxes page, and broader fitment formats on insert packaging.
Stop the box failing
Glass is dense, so the box is carrying real weight, often stacked. That points at a heavier board than the size alone would suggest, and at a construction that does not rely on a single closure. Choose the grade on the filled weight and the transit route rather than on the dimensions, which is the argument set out on single wall vs double wall corrugated.
Seal the box properly. Tape the centre seam and both edge seams on the top and the bottom, so the flaps cannot peel open under load. A box that opens in transit has effectively no packaging at all.
When to double box
Double boxing means the product sits in an inner box, and that inner box sits inside an outer box with 2 to 3 in of cushioning all round. It is the strongest commonly used method for fragile or high value glass, because the outer box absorbs the impact and the inner box never takes a direct hit. It costs two boxes and more freight cube, so use it where the product justifies it: laboratory glass, fine fragrance, spirits, art glass, anything that cannot simply be replaced.
Details that decide the outcome
- Immobilise the closure. A cap that loosens in transit leaks, and liquid weakens board fast.
- Orient deliberately. Bottles usually travel better upright, and orientation arrows on the outer help even though they are not guaranteed to be followed.
- Do not rely on a fragile label. Treat it as a courtesy, not as protection. Design the pack to survive being handled as ordinary freight.
- Test your own pack. Fill it, seal it, and drop it from around waist height onto each face and a corner. Whatever breaks tells you where to add material.
Order minimum and schedule
Shippers, partitions and fitments each start at 100 units, from about $0.48 per unit at bulk volumes, confirmed on your written quote. The cutting die, the printing plates, design support, US shipping and a digital proof are included, so a fitment cut to your exact bottle profile carries no tooling charge. Turnaround is stated per product across three lanes, rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days of production plus 2 to 5 days for delivery.
Send the bottle or jar measurements, the filled weight and how many travel per pack, and we will draw the partition and size the shipper around it. Start at request a quote, or see the glass carrier page for a ready format.
