Corrugated sheets and inserts: DIY partitions without a custom die
Corrugated sheets let you build layer pads, side liners and simple dividers inside a stock shipping box — a practical way to stop bottle-to-bottle and jar-to-jar contact without paying for a custom partitioned die on day one.
Updated 11 Sept 2026 · PackWorks By Velun, Karnal
What sheets are for
Flat corrugated board in 3-ply, 5-ply or 7-ply, cut as squares or rectangles. They are not a finished carton. You use them under loads, between layers, or scored into grids that drop into an RSC.
Patterns that work on a packing bench
Keep the knife work repeatable. Mark one master template on the first sheet; cut the rest from it.
- Layer pad: full footprint pad under/over a layer of jars
- U-pad: three-sided wrap for a single bottle in a larger cube
- Cross-grid: two slotted strips that interlock into four cells
- Side liner: strip that stiffens a weak face on a long thin carton
When to stop DIY
If you pack hundreds of identical multi-packs a day, labour on hand-cut grids will exceed a die-cut insert. If damage persists after a snug fit + pad, step to 5-ply or a purpose bottle carton. Sheets shine for pilots, gift assortments and uneven SKUs.
| Volume | Approach | Why |
|---|---|---|
| Samples / <50 orders/day | Hand-cut sheets | Zero tooling |
| 50–300/day mixed SKUs | Sheets + 2–3 stock box sizes | Flexibility |
| Stable multi-pack, high volume | Custom insert or partition | Labour wins |
Buy with the carton
PackWorks lists sheets under Sheets, Labels & Void Fill. Match ply to the threat: 3-ply pads for light layers, 5/7-ply for export bases. Add thermal labels on the same order if you print your own airway bills.