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A beauty brand was ready to launch a four-piece skincare set, and the pilot boxes came back from the co-packer with jars loose in the carton: caps scuffed, one serum bottle cracked at the shoulder. The relaunch used die-cut EVA inserts, and the difference shows up in two places that matter: the unboxing video and the returns log.
A cavity cut to the silhouette. Each insert is die-cut so a jar sits in its own recess with the shoulder supported and the label fully visible. Bottles do not rattle, palettes do not slide, and the customer lifts the whole set out in one piece. Because the foam is closed-cell, it sheds no fibers onto glass and wipes clean if a bottle leaks in transit.
Finish that matches the brand. The EVA laminates cleanly with paper, suede paper or fabric, so the insert reads black inside a black box or picks up a duo-tone accent on the edge. Density is chosen per set weight: light palettes ride on 20 to 30 kg/m3 foam, heavy glass jars need 45 kg/m3 so the cavity does not deform after shelf handling.
Spec list:
EV 3030 tray: 300 x 300 x 30 mm, 45 kg/m3 EVA, six-cavity jar layout.
EV 3525 tray: 350 x 250 x 25 mm, 30 kg/m3 EVA, bottle and palette mix.
EV 4040 tray: 400 x 400 x 40 mm, 20 kg/m3 EVA, full gift-set layout.
Sheet stock: 1000 x 2000 mm, gauges 2 / 3 / 5 / 8 mm, black standard.
Compression set: under 5% after 22 hours at 70 degrees C, per batch test.
Sampling flow. Send the artwork with bottle dimensions and the box inner size. We cut a first article from production stock, photograph it loaded, and ship it for your approval. Tooling for a new cavity layout takes 3 to 5 days; repeat orders run against the archived cutting rule so batch two matches batch one.
Send TOYOE your next set drawing and we will quote the insert, laminate and tooling in one reply.
