Your Guide to Choosing the Best Insert Material for Glass Bottle Packaging
Content Menu
● Common Insert Materials Compared
● Our Top Recommendation: Molded Pulp
● Packaging as a Brand Extension
● Success Story: A French Niche Perfume Brand
● Sustainable Packaging Is the Future
● Final Takeaway: Find the Perfect Fit
Glass bottles are a go-to choice for premium products like cosmetics, perfumes, and high-end beverages. They offer a luxurious look and feel, and their recyclability appeals to eco-conscious consumers. However, their fragile nature makes them vulnerable to damage during shipping. That's why choosing the right packaging insert isn't just about protecting your product—it's about protecting your brand.
A professional insert does more than just cushion a bottle. It should:
- Absorb shock and prevent direct contact with the outer box.
- Securely position the bottle to prevent movement.
- Enhance the unboxing experience for your customer.
- Reinforce your brand identity through design and materials.
Common Insert Materials Compared
Here's a breakdown of the most popular insert materials, along with their pros and cons.
Material | Features | Ideal For | Cost Level |
Cardboard/Paperboard | Lightweight, printable, offers moderate support. | Small businesses, brands on a budget, eco-conscious brands. | Low |
Corrugated Paper Insert | Excellent compression resistance and strong protection. | Health products, oral liquids, or anything requiring high shipping security. | Low-Medium |
Pulp Molded Insert | Biodegradable, excellent cushioning, can be custom-molded to fit the bottle's shape precisely. | Organic skincare, EU/US brands, and brands that prioritize sustainability. | Medium |
EVA Foam Insert | Offers superior shock absorption and a premium feel. Can be flocked for a velvety finish. Not eco-friendly. | High-end perfumes or luxury liquor gift boxes. | Medium-High |
Sponge Insert | Soft, scratch-resistant, and easily dyed. A more affordable alternative to EVA foam. | Beauty gift sets and niche perfume lines. | Medium |
EPE Foam Insert | Lightweight, shock-resistant, and water-resistant. | Pharmaceuticals, health products, or products that need extra protection during transit. | Low-Medium |
Plastic Blister Insert | Precise, transparent, and waterproof. Its use is declining due to environmental concerns. | Low-cost consumer goods, though less common today. | Low-Medium |
Our Top Recommendation: Molded Pulp
For many brands, molded pulp is the ideal choice. Made from recycled paper pulp, it's fully biodegradable and can be custom-molded to perfectly fit your glass bottle. This not only provides superior cushioning but also aligns with the growing demand for sustainable packaging.
It's a material that proves you don't have to sacrifice protection for eco-friendliness.
Packaging as a Brand Extension
Your packaging insert is an opportunity to extend your brand's story. Consider these design elements to enhance the unboxing experience:
- Print your brand logo or a slogan directly on the insert.
- Coordinate the color, material, and style with your outer box for a cohesive look.
- Choose eco-friendly materials to appeal to environmentally aware consumers, especially Gen Z.
Success Story: A French Niche Perfume Brand
A French perfume brand wanted to align its packaging with its "natural & sustainable" philosophy. They were using EVA foam, which provided great protection but didn't fit their brand values. We helped them switch to custom molded pulp trays with a foil-stamped logo.
The results were impressive:
- Zero breakage during shipping.
- Packaging aligned with brand values.
- Elevated unboxing experience, leading to more social media shares.
- An 18% increase in sales within three months.
This case study demonstrates how the right packaging can not only protect your product but also directly impact your bottom line.
Sustainable Packaging Is the Future
As environmental awareness grows, sustainable packaging is becoming a key brand differentiator. By choosing recyclable and biodegradable materials, you can reduce your carbon footprint and boost your brand reputation.
At AC Packaging, we offer a range of eco-friendly solutions, including:
Biodegradable molded pulp
Recycled corrugated inserts
Foldable paper structures
Final Takeaway: Find the Perfect Fit
The best insert material for your glass bottles depends on your unique needs. We recommend considering three factors: protection, cost, and brand aesthetic.
For small bottles on a limited budget: A simple cardboard or paperboard insert is a great starting point.
For heavy bottles needing maximum protection: Opt for corrugated or EPE pearl cotton inserts.
For premium brands focused on experience: Go with EVA foam or molded pulp with custom printing.
For brands with a strong eco-friendly focus: Molded pulp is your best choice.
Ready to find the perfect packaging solution for your brand?


