Alcohol is one of the least forgiving categories to pick and pack. Bottles are heavy, fragile and glass-on-glass, orders often mix wine, spirits and beer in one carton, and a single breakage can write off the whole parcel and stain everything in it. The packaging you choose is what stands between a clean delivery and a leaking box. This guide covers how liquor pick and pack works and how to pack alcohol so it arrives intact and the freight stays sensible.
What makes liquor fulfilment different
- Weight. A six-pack of wine is around 8 to 9 kg. Freight is billed on real weight here, not cubic, so the carton and dunnage weight matters too.
- Fragility. Glass fails on impact and on glass-to-glass contact. Bottles must not touch each other or the carton wall.
- Mixed orders. Wine bottles, spirit bottles, cans and gift packs of different shapes in one order need a divider system that adapts.
- Leak consequences. One broken bottle ruins the other contents and can damage other parcels in the vehicle.
- Compliance. Alcohol shipments need an adult-signature service and correct labelling; some carriers restrict them.
The workflow is the standard pick and pack process, with packing as the critical control point.
How to pack alcohol for transit
Moulded inserts are the standard
Pulp or moulded-fibre bottle inserts hold each bottle in its own cell, away from its neighbours and the carton wall. They are recyclable, absorb shock, and speed up packing because the packer just drops bottles into cells. For mixed orders, use inserts sized to your most common bottle plus adjustable dividers for the rest.
The carton has to carry the weight
Use double-wall board rated for the filled weight. A single-wall grocery carton will slump or burst under a stacked pallet of wine.
Seal so it holds first time
A strip of water activated tape top and bottom bonds into the board and holds a heavy carton through handling, without the multiple plastic-tape passes that slow the bench.
Fill every void
Any space a bottle can move into is a breakage waiting to happen. Paper void fill or additional pulp packs lock the load.
Mark it correctly
This-way-up and fragile marking, and the adult-signature label the carrier requires.
Freight: weight is the lever, not cube
Because alcohol is dense, parcels usually bill on actual weight. The savings come from not over-building the packaging: right-sized cartons so you are not shipping empty board and fill, and inserts that protect with less material than loose wrapping. Standardise on a small number of carton sizes matched to 3, 6 and 12-bottle orders. See where pick and pack fees come from.
In-house or outsourced?
Liquor picking is simple; the risk is all in the packing. Many producers and retailers keep it in-house precisely so they control the pack quality. If you are considering a fulfilment provider, check they use a proper bottle-insert system and will pack to your spec, then compare using contract packing versus smart in-house packaging. Carewell Group can support storage and dispatch and supply the packaging; we are not a contract packing, filling or bottling service.
How Carewell Group helps
Carewell Group is an Australian packaging manufacturer and supplier, including beverage and food packaging. For liquor fulfilment we provide:
- Moulded-fibre and pulp bottle inserts for wine, spirits and mixed orders.
- Double-wall cartons rated for filled weight, in 3, 6 and 12-bottle sizes.
- Paper void fill, edge protection and water activated tape with dispensers.
- Custom print on cartons and tape, and a parcel-profiling review to standardise your carton range.
Carewell can meet all your packaging needs for your business. Talk to our expert and we will work to your required MOQ. Call +61 (02) 8760 1491 or request samples and a sizing review. See also pick and pack for food and pick and pack solutions.
Frequently asked questions
How do you pack alcohol for shipping?
Use moulded-fibre bottle inserts so each bottle sits in its own cell away from others and the wall, in a double-wall carton rated for the filled weight, sealed with water activated tape and with every void filled.
Why does one broken bottle matter so much?
Glass shards and liquid ruin the rest of the order, can damage other parcels in the vehicle, and force a full replacement plus a claim.
Is liquor freight billed on weight or cube?
Usually actual weight, because bottles are dense. Savings come from right-sized cartons and efficient inserts rather than cube reduction.
Does Carewell bottle or fill alcohol?
No. Carewell supplies the packaging, inserts, cartons and tape, and can support storage and dispatch. We are not a bottling, filling or contract packing service.
Sources
- Australia Post, sending alcohol and dangerous or restricted goods: auspost.com.au
- Australia Post, cubic weight and parcel sizing: auspost.com.au
Written by Alif Vasaya, digital and content strategy, Carewell Group. Carewell Group is an Australian packaging, food packaging, tape, industrial safety and 3PL supplier serving all of Australia. Last updated 10 September 2026.