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Production & PackagingBased on 7 community discussions

What protective packaging solutions should we use to reduce bottle breakages during shipping?

Members recommend using robust pulp-insert and Flexi-Hex sleeve solutions as the most effective approach to prevent breakages during courier transit. Key options:

- **WBC pulp-safe boxes** — Members report these are "almost indestructible" even with rough handling by major couriers (UPS, DHL, DPD, APC, DX). The pulp-safe insert design with dividers provides reliable protection for spirits bottles. - **Flexi-Hex boxes with pinch-top design** — Described as "pretty damn bomb proof." The traditional pinch-top version is preferred by members over newer pop-up variants, which some felt matched the cheaper Kite quality. - **Kite boxes + Flexi-Hex sleeve combo** — A budget-friendly option. Kite is substantially cheaper than Forms Plus for a basic solution, though quality is characterized as "cheap and cheerful." - **Forms Plus + official Flexi-Hex pop-up box and sleeve combo** — More convenient but pricier. Members note Forms Plus will negotiate on price if you request a quote by email (they knocked £25 off one order), though it still may not undercut Kite.

**Caveats:** Courier performance varies; members emphasize that choosing "bullet proof packaging" combined with a competitive courier rate card and adequate insurance is more reliable than expecting consistent service from any single courier operator. The newer Flexi-Hex pop-up boxes don't match the quality of the original pinch-top design.

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