Spilling the secrets on drinks packaging

Colton Whitew Line

Packaging and transporting drinks can be a delicate task, which is why using the right materials to protect them is crucial. Here, we share the various considerations around creating robust – yet attractive – packaging for drinks.

 

Choosing the right corrugated board grade

The foundation of any reliable drinks packaging is the corrugated board itself. In the UK, corrugated boards are classified by flute type and wall construction; for example, single wall (B, C, E) or double wall (BC, EB). The outer liner paper also plays a key role, with kraft (made from virgin fibres) preferred for its strength and excellent printability, whilst a recycled (test) liner may be preferred for certain sustainability agendas.

For standard glass bottles, the grade of the boards in your packaging can make all the difference to your products’ protection:

  • Single-wall grades often used for bulk transit of drinks packaging, glass bottles or cans, where delivery is on pallets e.g. delivery to the retail network or wholesalers.
  • Double-wall grades, such as BC or EB provide added durability and are suited to D2C sales through the courier network due to their additional protection. In addition, most glass drinks packaging through the courier network would use some sort of corrugated divisions or fittings to mitigate against glass bottles banging into each other and smashing
  • For more refined drinks packaging, or for inner presentation layers in the design of your drinks packaging, E-flute board delivers a smoother surface which is perfect for high-quality print finishes
  • High-performance flutings and kraft inner linings can be applied to the board for chilled drinks or brewery environments, where condensation from the cold can compromise the structural integrity of the packaging.

Protecting bottles in transit

Damage in transit can lead to breakages and returns – which in turn mean added costs for your business. This is why internal fittings, die-cut inserts and custom dividers are essential for multi-bottle packs.

We design inserts that eliminate bottle movement and prevent glass from clinking and potentially getting damaged in transit. Whether you’re shipping a six-pack, or a 24-bottle case, our corrugated cardboard designs ensure bottles arrive intact.

For even better protection, you might consider integrating features such as:

  • Suspension inserts for an air-gap buffer
  • Pre-assembled corrugated divisions for increased speed on the packing line
  • Cushioned contact points to absorb impact.

Die-cutting for visual appeal

Corrugated cardboard drinks packaging doesn’t have to be purely functional. With advanced die-cutting, you can transform boxes and packaging into a key part of your brand story.

From window cut-outs to carry handles, clever design features can elevate your drinks packaging – especially during seasonal promotions, or for retail. We work with drinks brands to develop customised die-cut designs, turning packaging into a way to showcase products such as in gift boxes for gift sets.

Sustainability and compliance

Sustainability is more than just a buzzword in 2025 – it’s becoming a legal and financial requirement. More and more, brands must minimise waste, use recyclable materials and reduce packaging weight wherever possible – which is where our corrugated cardboard designs come in.

Our corrugated cardboard is 100% recyclable, and we can advise on the optimum recycled content if this supports our customer’s agenda, helping streamline packaging designs to reduce material use in their packaging, without compromising on protection or overall design.

 

Previous projects

Don’t just take our word for it – we’ve worked on a number of drinks packaging projects with some well-known clients. Here’s a case study about our work with Brixton Gin, and how we provided the perfect packaging solution for their products, and below are some other projects we’ve worked on.

 

Summary

When it comes to drinks packaging, corrugated cardboard continues to lead the way – delivering protection to fragile contents, visual appeal and versatility, and eco-friendly credentials.

Get in touch with our team to find out more about how we could help your drinks brand.

Posted on: 30 July 2025
Posted in: Industry Insights

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