Assembly Guide

How to Assemble HEXPAND Bottle Packaging

Follow these illustrated steps to prepare the protective insert, secure each bottle, and place the completed assembly into its matching outer carton.

Before you begin

Lay the insert flat on a clean surface. Pre-break all indicated scores before loading the bottle or bottles. Have the matching outer carton ready for the completed assembly.

Single-Bottle Insert

1-Bottle Assembly

Flat one-bottle HEXPAND insert with score locations

Step 1

Pre-break the scores

Gently flex the insert along each scored line so the sections will fold easily.

Bottle positioned in the folded one-bottle insert

Step 2

Fold and position the bottle

Fold the perforated sections upward as shown, then place the bottle into the formed opening.

Expandable honeycomb panel being stretched beside a bottle

Step 3

Expand the protective panel

Hold the insert steady and pull the end panel outward until the honeycomb section is fully expanded.

End panel placed over the neck of a bottle

Step 4

Secure the bottle neck

Bring the expanded panel up and over the bottle, then place the round opening over the bottle neck.

Completed one-bottle protective assembly being inserted into an outer carton

Step 5

Place it in the carton

Keep the completed assembly together and carefully lower it into the matching outer carton.

Three-Bottle Insert

3-Bottle Assembly

Flat three-bottle HEXPAND insert with score locations

Step 1

Pre-break the scores

Gently flex the insert along each scored line before beginning the assembly.

Three-bottle insert folded along its perforated scores

Step 2

Fold the insert

Fold the perforated sections upward to form the three bottle positions.

Three bottles loaded into the folded protective insert

Step 3

Load all three bottles

Insert the bottles one at a time, placing each bottle through its corresponding opening.

All three expandable bottom panels stretched outward

Step 4

Expand each bottom panel

Stretch the first honeycomb panel outward, then repeat with the middle and third panels.

Expanded bottom section folded upward around three bottles

Step 5

Fold the bottom upward

Lift the expanded bottom section toward the bottles as shown.

Hole in an expanded panel being placed over a bottle neck

Step 6

Secure each bottle neck

Pull the first expanded panel to the top and place its opening over the bottle neck. Repeat for the middle and third bottles.

Completed three-bottle protective insert assembly

Step 7

Check the completed assembly

Confirm that each neck is held by its panel and the protective honeycomb sections are fully expanded before placing the assembly into its matching outer carton.

Need help with your bottle packaging?

Our packaging specialists can help you select the right insert and outer carton for your application.

Contact Packaging HERO