Paper-based protective packaging manufacturer Hexacomb has developed a new paper-based, cost-reducing HexStack packaging system for the transport of larger liquid-filled bottles.

Said to feature a single layer of Hexacomb custom-die cut honeycomb material to accommodate the specific bottle neck, the new HexStack can minimize product damage during transport.

The pad is laid on top of a layer of bottles, while the closures and necks are inserted into the die cuts, whose orifice rests on the shoulder by surrounding the bottle neck, immobilizing the container.

The closure above the die-cut orifice slightly protrudes and can nest into the container's base above it for bottle designs with a concave base.

Using shrink wrapping method, larger liquid bottles can be stacked three layers high for transport and retail display, the company noted.

At the retail location, HexStack can usually support a three-layer high pallet load, while some other methods are only double stacked.

Made primarily from renewable wood fibers which have been engineered into a honeycomb configuration, HexStack pads contain recycled content which helps support brand owner environmental initiatives and are recyclable in corrugated recycling streams.