Multi-Bottle and In-Store Packing

Load and Base Support

A still-wine bottle runs 1.2 to 1.8 kg filled. Champagne and heavy-based spirits exceed 2 kg. We set box load capacity at least twice the actual filled weight, not the empty-bottle weight. That margin shows up in the base first.

For bases, we spec a reinforcing card, a double layer, or an EVA or moulded-pulp tray carrying the load. Lid-and-base and drawer formats are highest risk at the base, so we check that area on the first sample before moving to printed sample.

Handle Reinforcement

Handle failure is the most common complaint on multi-bottle boxes. We add a folded-back paper layer at the handle position. The folded layer distributes the pull force instead of leaving the cut edge to tear. We apply the same handle treatment to the 4/6-bottle magnetic box and the windowed corrugated carrier in the range.

In-Store Divider Design

For in-store assembly, the divider is where errors happen. We build in two fixes. Orientation arrows show the correct face and direction. Asymmetric locating tabs mean a reversed divider physically will not seat. Structure solves it, not training. That removes the main operator mistake before it reaches the floor.

Where a single box must take two bottle diameters, we put two fold positions on one divider. They are marked A and B on the reverse. The operator folds to A for one bottle type or to B for the other. No extra divider SKU, no guesswork.

Window and Label Alignment

Window position is verified against both bottle labels, not sized from one bottle type. We check the window opening against label height and side placement on the actual bottles, because a window that looks right on one SKU can crop another. The same check applies to the windowed corrugated carrier.

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