Breakage-proof beverage packaging is engineered, not improvised. We match every can, bottle and pouch format to a tested pack-out that immobilizes the product, contains a leak if one happens and keeps the box as small and light as possible.
What actually breaks beverages in transit
Most beverage damage in parcel networks comes from drops, impacts on conveyors and sorters, crushing under heavier parcels and vibration over long distances. Cans dent at the rim and chime, then pinhole or burst under pressure. Glass fails at the base and shoulder when bottles touch each other or the box wall. PET bottles lose caps or crack at the neck under compression.
The common thread is movement. Product that can shift inside the carton gathers momentum and strikes something. Good beverage packaging removes that movement: every unit held in its own cell, separated from neighbors and suspended away from the outer walls, with the load shared across the shipper instead of concentrated on one corner.
Pack-out options by format
Cans ship best in molded-pulp trays or corrugated partitions sized to the can diameter, which keeps them from rolling and protects the rims. Slim, sleek and standard cans each need their own insert. Glass bottles typically use molded-pulp shippers or die-cut corrugated cells that hold the neck and base, often with a poly liner bag to contain liquid if a bottle fails.
PET bottles and jugs need less impact protection but more attention to cap security and crush resistance. Powder tubs, stick-pack cartons and coffee bags are rarely fragile, but they still need right-sized cartons so heavy items do not crush lighter ones in mixed orders. We favor recyclable fiber-based materials where they perform, and keep plastic liners for cases where leak containment really matters.
Drop testing before launch
Every new pack-out is drop-tested before it carries customer orders. We pack your actual product in the proposed shipper and run a structured sequence of drops onto faces, edges and corners, modeled on the parcel test procedures published by the International Safe Transit Association (ISTA). Results are documented with photos.
If a pack-out fails, we adjust the insert, carton grade or orientation and retest. If you need a formal certified ISTA test for a retailer or marketplace, we can prepare samples for an accredited lab. Testing up front costs far less than discovering a weak pack-out through customer complaints, carrier damage claims and replacement shipments.
Balancing protection, cost and sustainability
More packaging is not automatically better. Every extra inch of carton adds dimensional weight and every extra layer adds material cost and waste. The goal is the lightest, smallest pack-out that passes testing for that format.
We review damage data by SKU, pack-out and lane after launch. When a specific route or season causes problems, such as freeze risk on northern lanes in winter, we can apply a stronger pack-out to just those orders instead of upgrading everything. When damage is near zero, we look for ways to reduce material. You receive a clear recommendation and the trade-offs, and you choose.
What's included
- Molded-pulp trays and corrugated partitions by can size
- Glass bottle cells with neck and base support
- Poly liner bags for leak containment
- ISTA-modeled drop testing with photo documentation
- Seasonal pack-out rules by lane
- Damage tracking by SKU, pack-out and carrier
- Recyclable fiber-first material options
Frequently asked questions
What is the best way to ship glass bottles?
The best way to ship glass bottles is in a molded-pulp or die-cut corrugated insert that holds each bottle in its own cell, away from other bottles and the box walls, inside a right-sized double-wall or sturdy single-wall shipper. A poly liner bag adds leak containment.
Do carriers accept liquids in parcels?
Major parcel carriers accept non-hazardous liquids such as non-alcoholic beverages when they are packaged to prevent leakage and breakage. Each carrier publishes packaging guidelines, and damaged leaking parcels can be held or returned, so tested packaging matters.
Can I use my own branded packaging?
Yes, as long as it passes drop testing for the formats it carries. We can also help you specify a branded insert or shipper that performs well and keeps dimensional weight low.
Is sustainable beverage packaging protective enough?
Often, yes. Molded pulp made from recycled fiber is widely used for cans and glass and performs well in testing. We validate any sustainable option with the same drop tests as any other pack-out.