Packaging Reference Library · Technical Reference

Partitions, Pads and Corrugated Inserts

Partitions, pads and inserts are the interior pieces that divide, layer and hold products inside a box. This sheet explains the types, how to measure them and what to ask before quoting.

Ref PK-0107

Draft, open for review. Check every value against the governing standard and the manufacturer’s data before use.

What it is

Partitions are slotted strips that interlock to form a grid of cells, so each item has its own pocket. They are made from chipboard, corrugated board or plastic. Pads are flat sheets used in the bottom or top of a box, between layers or as reinforcement. Layer pads and slip sheets separate tiers on a pallet. Die-cut inserts are corrugated pieces cut and folded to hold a specific product in place. Inserts protect products from contact damage, add stacking strength and speed packing.

How to measure

Measure the inside of the box: length by width by depth.
For partitions, count the cells along the length and width, for example 3 by 4 for 12 cells.
Measure the height the partition must be. It is often equal to or slightly less than the inside depth.
Measure the item to confirm each cell is large enough.
For pads, measure the inside length and width. Pads are cut slightly under the box inside dimensions so they drop in.
For die-cut inserts, send a sample of the product and the box.

Insert types

Type	Material	Typical use	Notes
Chipboard partition	Solid paperboard	Light glass, bottles, small parts	Thin walls; most cells per box
Corrugated partition	Single-wall or double-wall board	Heavier glass, jars, parts	Adds stacking strength
Plastic partition	Corrugated plastic	Returnable totes, moist areas	Reusable; higher cost
Corrugated pad	Single or double wall	Box bottoms, layer separation	Order by length by width
Slip sheet or tier sheet	Corrugated, solid fiber or plastic	Pallet layers	Order to pallet footprint
Die-cut insert	Corrugated	Holding a specific product	Needs tooling and a sample
Scored or folded pad	Corrugated	Wrapping edges and corners	Scores set the fold lines

Key points

Partition sizes are given by cell count and the box inside dimensions, plus height.
Ask if the partition must be full height or a shorter partition with a pad on top.
Flute direction matters on pads used for strength. See the flute profile chart.
Die-cut inserts usually have a minimum quantity because of tooling.
Food contact or recycled content needs may limit the board choice.

Common mistakes

Quoting partitions from outside box dimensions.
Making cells exactly the item size so packing is slow and products jam.
Forgetting a top pad so the partition does not hold items in place.
Using chipboard partitions for products heavy enough to crush them.

Governing standards: No single product standard. Board grades are certified on the box maker's certificate; see the box maker's certificate decoder.

Reference only. Verify against the current governing code or standard, the manufacturer's data and the project documents before use. Apps for Distributors disclaims liability arising from reliance on this reference.

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