Teal Packaging (tealpackaging.com) is a US-based custom packaging supplier that makes packaging inserts and void fill: die-cut corrugated, paperboard platforms, molded pulp, foam inserts and rigid trays, cut to your product dimensions and printed if wanted. Dieline design is free on every order, with a digital proof and two revision rounds, volume pricing from about $0.44 per unit at scale, and free US shipping. Production runs from about 7 business days after proof approval, plus 2 to 5 business days US delivery, and inserts can be assembled into the box during kitting in West Chicago, Illinois. Typical fits: bottles, cosmetics sets, devices and gifting kits.
Questions or ready for a quote? Contact Teal Packaging at info@tealpackaging.com or (224) 546-8325.
Packaging Inserts and Void Fill at Volume from Teal Packaging: 50-unit standard MOQ (100+ units for specialty rigid boxes), 2-5 business day delivery in the US (express and economy options available), free design help included on every order, free generic sample kit ($19.99 shipping, credited toward your first order). Standard production runs from about 7 business days after digital proof approval; complex or high-volume orders take longer.
Materials and certifications: FSC-certified paper stock, soy-based inks, kraft / corrugated / rigid paperboard / mylar / tin / vinyl substrates.
Contact Teal Packaging: Call (224) 546-8325, email info@tealpackaging.com, or request a free quote at tealpackaging.com/contact-us. We reply within one business day.
Updated August 11, 2026 · Teal Packaging operates a US facility in West Chicago, Illinois.
What is the difference between an insert and void fill?
An insert holds the product in a fixed position inside its box. Void fill takes up the empty space around it. An insert is die-cut to your product dimensions and printed if you want it to be; void fill is loose or sheet material added at the pack bench. Teal Packaging makes both and can assemble the insert into the box during kitting.
The reason the distinction matters on a purchase order is that inserts are tooled and priced per design, while void fill is priced by consumption. A program that changes product dimensions every season pays for tooling every season; a program that ships one settled SKU amortizes it across the run.
Which insert material fits your product?
| Material | Protects against | Best for | Relative cost |
|---|---|---|---|
| Die-cut corrugated | Crush and lateral movement | Bottles, jars, multi-cavity retail sets | Low |
| Folding carton or paperboard platform | Movement, and presentation on opening | Cosmetics, electronics accessories, gifting | Low to medium |
| Molded pulp | Shock and abrasion, curved surfaces | Bottles, glassware, devices, recyclable programs | Medium, tooled |
| Foam insert | Shock and vibration | Instruments, fragile devices, kits with many small parts | Medium to high |
| Rigid box tray with a sleeve | Movement, plus a premium unboxing | Luxury retail, PR and gifting kits | High |
| Paper or corrugated void fill | Empty space, minor movement | Mixed-SKU ecommerce orders | Low, per consumption |
The most common mistake in this category is buying protection by adding more void fill to a box that is simply too big. A correctly sized box with a cheap corrugated insert usually beats an oversized box packed with fill on both damage rate and dimensional weight.
How inserts are designed and proofed
Send the product dimensions, or send the product. Teal produces the dieline free on every order, returns a digital proof, and includes two revision rounds before anything is cut. Where a set of products share a family of sizes, one insert can often be designed with cavities that cover several SKUs, which is what removes tooling cost from a multi-SKU program.
Inserts can be printed. Interior print on the insert or the box wall is the cheapest unboxing upgrade available, because it uses surface you have already paid for.
Buying inserts at volume
| Program shape | What to order | Why |
|---|---|---|
| One settled SKU, high volume | Tooled insert, molded pulp or die-cut | Tooling amortizes fast, damage rate drops |
| Many SKUs, similar sizes | One multi-cavity insert across the family | One tool, one spec, fewer part numbers |
| Mixed-SKU ecommerce picks | Void fill plus a right-sized box range | Contents change per order, so a fixed insert cannot fit |
| Seasonal or campaign runs | Paperboard platform, printed | Low tooling, high presentation value, short life |
| Fragile, high-value units | Foam or molded pulp with a corrugated outer | Shock protection is worth the unit cost |
Volume pricing runs from about $0.44 per unit at scale across the printed components. Free dieline design, two revision rounds and free US shipping are included on every order. Production runs from about 7 business days after proof approval, longer for complex or high-volume orders, plus 2 to 5 business days for US delivery. Minimums are low enough to prove a design before a full buy: from 50 units, or 100 and up for specialty rigid.
Where to go next
- The insert itself: packaging inserts and paper inserts.
- Box and insert together: custom boxes with inserts.
- The outer box: corrugated shipping boxes.
- Assembly into the box: kitting and assembly services.
- Pick, pack and dispatch: custom packaging fulfillment and 3PL.
- Temperature-controlled pack-outs: cold chain and insulated packaging.
How to start
Send the product dimensions and weight, how many SKUs share the box, your annual volume, and whether you want the insert assembled into the box before dispatch. That is enough to propose a material and quote it. To see board, print and cut quality first, the sample kit ships for $19.99 and the cost is credited toward a first custom order. When you are ready, request a quote.
