We arrange bottles in a controlled layer, separate and support them with cardboard, add the next bottle layer and continue until the specified transport height is reached. The completed stack is then secured with plastic film as part of the shipment preparation. The exact cell layout, layer count and support arrangement follow the bottle and transport configuration.

The 80% figure is our first-party comparison between this applicable layered stacking route and our previous carton-intensive packing route. It measures the reduction in paper used for those compared configurations. It is not an industry average and should not be applied to another bottle, pack count or transport system without a new comparison.

No. Cardboard remains part of the structure because it separates, organises and supports bottle layers. The method reduces reliance on individual or small-group cartons; it does not create a paper-free shipment. It also uses plastic film to secure the completed stack, so claims must describe the actual material change rather than call the whole route plastic-free.

No. Suitability depends on bottle geometry, base stability, neck projection, surface decoration, glass weight, contact risk, layer layout and the handling route. A stable undecorated bottle may need a different separator or protection plan from a coated, irregular or easily scratched bottle.

The cardboard cell or divider arrangement controls bottle position and reduces direct glass-to-glass contact in the specified layout. Its geometry must match the bottle diameter, shape and vulnerable areas. Buyers should provide the final bottle drawing and decoration because a divider designed for one bottle may not protect another structure correctly.

Stack stability, compression, vibration, impact, pallet handling, container loading, humidity and the risk of rubbing or decoration damage still need to be considered. Reducing paper does not remove the need to verify protection. The relevant checks must represent the actual pallet, route and handling conditions rather than an unpacked bottle alone.

The film helps secure the assembled layers and limit movement during handling and shipment preparation. The film specification and wrapping route depend on load weight, pallet pattern and transport conditions. We do not describe the route as plastic-free, and buyers should state any film-material, recovery or destination-market requirements in the RFQ.

It changes the receiving unit from many individual cartons to larger organised layers. The buyer should confirm whether the warehouse can handle the pallet, remove the film safely, lift bottle layers or trays and feed the next filling or decoration operation without creating extra manual damage. Packaging efficiency must work at both the shipping and receiving ends.

Provide the bottle drawing, weight, surface decoration, quantity per shipment, required unit protection, pallet and container conditions, loading and unloading method, warehouse equipment, transport route, humidity exposure and any test requirements. Tell us whether bottles arrive for automated filling, manual handling or further decoration so the stack can be reviewed as part of the complete supply chain.

Approve the bottle arrangement, cardboard cell and layer design, pallet pattern, stack height, securing method, receiving procedure and the agreed transport-validation route. The first shipment or trial load should represent the intended bottle, decoration and logistics conditions. The two factory images illustrate the structure but do not replace physical approval or transport verification.