Packaging Inserts Guide: EVA, Foam, Velvet or Paper Trays?
A packaging insert is the internal structure that holds a product in place inside the box; the mainstream options are EVA foam, PU or PE foam, flocked velvet, moulded pulp, and paper or card trays. The choice controls two things at once: how well the product survives shipping, and how premium the box feels when it opens. This guide compares them on protection, presentation and cost, then maps them to product categories.
The five insert types at a glance
| Insert | Protection | Look and feel | Relative cost | Best for |
|---|---|---|---|---|
| EVA foam (die-cut) | Excellent - firm and precise | Matte, technical | Medium | Electronics, devices, tools, heavy bottles |
| PU / PE foam | Good - soft, absorbing | Soft, matte | Low-medium | Fragile glass, cosmetics, general gifts |
| Flocked velvet (over EVA or paper) | Good - cushioned | Luxury, soft, light-catching | Medium-high | Jewelry, watches, pens |
| Moulded pulp | Very good - rigid, supportive | Natural, recyclable | Medium | Wine, spirits, heavy gift sets |
| Paper / card tray | Good - light items | Clean, printable | Low | Cosmetic sets, sachets, subscriptions |
Choosing by product category
- Jewelry and watches: flocked velvet over an EVA core, with a ribbon lift so the piece rises as the lid opens. See jewelry packaging.
- Electronics: die-cut EVA with a finger notch, plus an anti-static option for boards. See electronics packaging.
- Cosmetics and skincare: an EVA cradle or printed paper tray with a tissue liner - light, precise and fast to pack. See cosmetics packaging.
- Wine and spirits: moulded pulp or EVA with a neck rest and a base ring, so a 1.5 kg bottle cannot move. See wine and spirits packaging.
- Toys and hobby kits: multi-compartment paper trays with a printed part map. See toys and hobby packaging.
- Supplements: die-cut collars and paper trays that keep bottles upright through courier networks. See supplement packaging.
Protection versus presentation
Protection needs compression resistance and retention - the product must not move, and the box must resist stacking. Presentation needs depth: a recess deep enough that the product sits below the rim, and a surface that contrasts with the product. A two-layer insert gives you both: a structural EVA or pulp base for protection, with a velvet or printed paper surface for the reveal. Elastic straps and ribbon pulls are the usual answer for soft goods and accessories that cannot be cradled.
How inserts change cost and lead time
Insert pricing has three parts: the die or tooling, the material, and the assembly labour. Paper trays are the cheapest and print like the rest of the box; PE foam is next; EVA and flocked velvet cost more per unit; hand-fabricated inserts (foam wrapped in velvet with ribbon) are the top of the range and add the most assembly time.
The good news: your MOQ stays at 100 pcs per design. A custom die-cut insert does add a small tooling cost and a few extra days to sampling, and we always quote the insert together with the box so you see one real landed number rather than two partial ones.
Specifying an insert correctly
- Product dimensions, plus weight in grams
- How the customer should remove it - one hand, two hands, or tipped out
- Drop height and shipping method the pack must survive
- Whether the insert must be plastic-free or recyclable in your market
- Whether the pack is reused (inserts that must survive repeated use need a denser material)
- Print or branding required on the insert itself
Before production, drop and shake the packed sample. If you can hear the product move, the insert is not finished - we re-cut the die until it is silent.
FAQ
Q: What is the most common packaging insert?
A: Die-cut EVA foam for electronics and heavy items, and flocked velvet over EVA for jewelry and watches. Paper trays are the fastest growing option for brands cutting plastic.
Q: Can I get a plastic-free insert?
A: Yes - moulded pulp, die-cut card trays and paper wraps replace foam entirely, and we can supply material declarations for EU packaging-waste reporting.
Q: Do custom inserts raise my MOQ?
A: No. The MOQ stays at 100 pcs per design; a custom die adds a small tooling cost and a few days to sampling.
Q: How do I know the insert will protect my product?
A: We prototype with your actual product and weight, then drop and shake test the packed sample before mass production.
Send us your product and we will recommend the right insert with a free 3D preview - samples ship in 5-7 days and the fee is refunded on your first order. Get a quote or talk to an engineer.
Structural designers & print specialists, Shenzhen
