Panel Configuration · Nested

Cookie Cut

A cookie cut is made by slicing through both top and bottom facing papers in a single plane while leaving the central core material intact. This allows for the pieces adjacent to the cookie-cut line to be cleanly separated at the point of use without needing any tools. The modification is useful for keeping small pieces together on a pallet, SKU consolidation, and greater flexibility during packaging operations.

How it works.

The panel is passed through a machine fitted with blades set to a controlled depth — cutting just through the top facing paper and slightly into the core from above, then just through the bottom facing paper and slightly into the core from below. The uncut core holds all the pieces together as a unit until they are ready to be separated.

At the point of use, operators separate individual pieces from the panel by pressing or pulling them apart by hand. The separation is clean and requires no cutting tools, reducing pack-out time and eliminating the risk of tool-related injury or contamination.

Technical Specifications

  • Cut Depth

    Through both facing papers into core from each side — leaving centre core intact

  • Piece Geometry

    Customer-specified — straight cuts, stepped cuts, or shaped profiles

  • Separation Method

    Hand separation — no tools required at point of use

  • Panel Compatibility

    Any flat panel within standard dimension ranges

Design considerations.

  • Multiple panels can be stacked for shipping. Pieces remain nested and do not shift during transit.

  • Cookie cutting can be combined with slit scoring for folded profiles that separate at point of use.

  • Piece dimensions should be specified with tolerances in mind. Discuss fit requirements with us before finalizing geometry.

Applications

Common applications.
Cookie Cuts can be implemented for a variety of applications. The examples below are illustrative starting points, not standard SKUs. Let’s develop your solution.

Protective Tray Inserts

Individual cushioned inserts produced nested in a panel — separated and placed in product trays or cartons at the point of pack-out.

Appliance Packaging

Custom-shaped pads and spacers for protecting appliance panels, glass doors, and control surfaces — one panel delivers multiple identical pieces.

Bottle & Glass Dividers

Flat honeycomb separators for protecting glass or ceramic products in layer packs — each divider separates cleanly by hand.

Battery & Electronics

Cushioned inserts for protecting sensitive components during transit — optimised cell size provides rigidity and energy absorption.

Multi-Piece Fitments

Multiple-part packaging fitments produced from a single panel. Operators peel pieces and assemble directly into the carton.

Retail Pack-Out

Consumer product packaging where a clean, easy-open insert is required — cookie-cut panels give a professional result.
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