Patent Publication Number: US-11643268-B2

Title: Apparatus and methods for packaging and shipping wine bottles

Description:
TECHNICAL FIELD 
     The present invention relates, generally, to ecologically sustainable methods and apparatus for manufacturing wine packaging materials and shipping containers and, more particularly, to an environmentally friendly packaging configuration for shipping wine bottles using molded fiber and corrugated materials. 
     BACKGROUND 
     Pollution caused by single use packaging materials is epidemic, scarring the global landscape and threatening the health of ecosystems and the various life forms that inhabit them. Trash comes into contact with waterways and oceans in the form of bits of Styrofoam and expanded polystyrene (EPS) packaging, to-go containers, thin film bags and photo-degraded plastic pellets. 
     Sustainable solutions for reducing plastic pollution, including both molded fiber and corrugated cardboard materials, are gaining momentum. However, continuing adoption requires these solutions to not only be good for the environment, but also competitive with current packaging and shipping materials from both a performance and a cost standpoint. The present invention involves an improved wine packaging and shipping assembly and related methods using molded fiber and corrugated components. In addition, the present invention replaces the traditional three-dimensional fiber molded top half of a wine packaging assembly with a single, planar, corrugated sheet, further reducing cost, weight, waste, and overall complexity. 
     By way of brief background, molded paper pulp (molded fiber) has been used since the 1930s to make containers, trays and other packages, but experienced a decline in the 1970s after the introduction of plastic foam packaging. Paper pulp can be produced from old newsprint, corrugated boxes and other plant fibers. Today, molded pulp packaging is widely used for electronics, household goods, automotive parts and medical products, and as an edge/corner protector or pallet tray for shipping electronic and other fragile components. Molds are made by machining a metal tool in the shape of a mirror image of the finished package. Holes are drilled through the tool and then a screen is attached to its surface. The vacuum is drawn through the holes while the screen prevents the pulp from clogging the holes. 
     Corrugated materials are available in different wall thicknesses, known as flutes sizes. In particular, corrugated material is comprised of three fiberboard layers; two linerboards and a middle sheet comprising a wave-shaped pattern of arches known as flutes. These flutes are adhesively sandwiched between the outer linerboards. 
     On end, flutes form rigid columns capable of supporting substantial weight. From the side of the board, the space between the flutes acts as a cushion to protect the container&#39;s contents. Flutes also serve as a thermal insulator, providing protection from sudden temperature changes. The linerboard provides additional strength and protects the flutes from damage. 
     Flutes are categorized by various sizes, known as flute profiles, ranging from A-flute (the largest) to F-flute and below (microflutes): 
     E-Flute: 1/16″ thick, 90 flutes per linear foot 
     B-Flute: ⅛″ thick, 47 flutes per linear foot 
     C-Flute: 3/16″ thick, 39 flutes per linear foot 
     A-Flute: ¼″ thick, 33 flutes per linear foot 
     The A-flute is the original corrugated flute design and is the thickest. A-flutes provide a high degree of cushioning for fragile products. The C-flute is the most widely used flute size, commonly used for packaging glass products. B-flutes provide a stiff, flat surface for high quality printing and die cutting. Developed for packaging canned goods, the B-flute is used for beverage trays, wrap-around blanks, glass-to-glass packs, and slipsheets. 
     Containing about 90 flutes per foot, the E-flute has high crush resistance and a relatively flat surface for high quality printing applications. The thin board profile of E-flute reduces outer box dimensions, and can help save storage space. The F-flute is used for specialty packaging, point-of-purchase displays, jewelry and cosmetic packages, and shoe boxes. In the United States, fast food chains are adopting F-flute materials in clamshell packaging. 
     In addition, the foregoing single flute configurations may be combined to form double flutes such as, for example, AE, BE, BC, AB, and the like. 
     Presently known non-petroleum based wine shipping assemblies include a molded fiber base (or bottom) component having individually partitioned cylindrical segments configured to receive six or twelve bottles. A molded fiber cap (or top) component includes corresponding individually partitioned conical segments configured to receive the top portions of the bottles such that, when the cap is placed over the bottles, each bottle is protected from contacting the other bottles. The entire assemble is received within a corrugated carton and sealed for shipment. 
     Non-standardized bottle sizes, shapes, and heights, coupled with manufacturing limitations on the size and shape of vacuum molded fiber cap components, limit the utility of the foregoing packaging assembly. For example, in many applications a gap exists between the top of the molded fiber base and the bottom of the molded fiber cap. To accommodate this deficiency, a corrugated divider includes a plurality of vertically oriented, orthogonal planar segments running between adjacent bottles to protect the bottles from contacting each other during shipment. However, the divider increases assembly and packing time, cost, material count, waste, and overall complexity. 
     Improved wine packaging and shipping assemblies are thus needed which overcome the limitations of the prior art. 
     Various features and characteristics will also become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and this background section. 
     BRIEF SUMMARY 
     Various embodiments of the present invention relate to wine packaging and shipping assemblies which include: i) a vacuum molded base component having a plurality of cylindrical concave columns within which respective bottles are placed; ii) a substantially planar single or double fluted corrugated sheet (which replaces the aforementioned divider) having a plurality of expandable holes aligned with the axes of the columns, with each hole configured to slidably receive a respective bottle neck therethrough; iii) an optional vacuum molded cap component for receiving the top portions of the bottles therewithin; and iv) an outer corrugated box within which the foregoing components are secured. 
     It should be noted that the various inventions described herein, while illustrated in the context of wine bottles, are not so limited. Those skilled in the art will appreciate that the inventions described herein may contemplate packaging and/or shipping containers for any products which need to avoid contact with one another during shipment. 
     Various other embodiments, aspects, and features are described in greater detail below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       Exemplary embodiments will hereinafter be described in conjunction with the appended drawing figures, wherein like numerals denote like elements, and: 
         FIG.  1    is a top view of an exemplary prior art bottom packaging component having a plurality of bottles disposed therein in accordance with various embodiments; 
         FIG.  2    is a side view of an exemplary prior art packaging system further including a cap portion for securing the tops of the bottles therein, showing a gap between the top of the bottom component and the bottom of the top component in accordance with various embodiments; 
         FIG.  3    is a perspective view of an exemplary prior art packaging system including a corrugated divider disposed within the aforementioned gap, the divider including interleaved orthogonal vertical segments extending between adjacent bottles in accordance with various embodiments; 
         FIG.  4    is perspective view of a planar bottle separator designed to replace the interleaved divider of  FIG.  3   , the separator including a plurality expandable holes for receiving bottle necks therethrough in accordance with various embodiments; 
         FIG.  5    is a side view of the assembly of  FIG.  4   , further including an optional top component including a plurality of generally conical segments for receiving the bottle tops in accordance with various embodiments; 
         FIG.  6    is a plan view of the separator shown in  FIGS.  4  and  5    in accordance with various embodiments; 
         FIG.  7    is an edge view of the separator depicting a double flute configuration in accordance with various embodiments; 
         FIG.  8    is a close up view of a partially expanded receptor viewed from the top of the planar separator in accordance with various embodiments; 
         FIG.  9    is a close-up view of an unexpanded receptor viewed from the bottom of the planar separator in accordance with various embodiments; 
         FIG.  10    is a perspective view of an exemplary separator shown securing a plurality of bottles within an outer box container in accordance with various embodiments; 
         FIG.  11    is a schematic diagram of a first exemplary separator depicting various dimensions in accordance with various embodiments; 
         FIG.  12    is a schematic diagram of a second exemplary separator depicting various dimensions in accordance with various embodiments; 
         FIG.  13    is a schematic diagram of a third exemplary separator depicting various dimensions in accordance with various embodiments; 
         FIG.  14    is a perspective view of an alternate embodiment of a two-tiered separator assembly securing a plurality of wine bottles in accordance with various embodiments; 
         FIG.  15    is a perspective view of the separator assembly of  FIG.  14    showing the folded flaps extending downwardly to hold the bottom portion of a bottle in place; and 
         FIG.  16    is a top plan view of the two tiered separator assembly of  FIGS.  14  and  15   , shown in the unfolded (planar) position. 
         FIG.  17    is a side elevation view of the assembly in  FIG.  10   , further including an optional top component (cap)  502  including a plurality of concave (generally conical) segments  504  for receiving the bottle tops, where the bottles are received within a bottom component  506 . A visual indicia of orientation  1704  is provided. The assembly, top component  502 , and the bottom component  506  are placed within a corrugated outer box  1702 . 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EXEMPLARY EMBODIMENTS 
     The following detailed description of the invention is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description. 
     Various embodiments of the present invention relate to packing and shipping assemblies for bottles comprising a fiber-based (or pulp-based) bottom receptacle for receiving a plurality of bottles, a planar divider for separating the bottles, and an optional cap component configured to retain the divider on the bottles during shipping. In a preferred embodiment the separator comprises a single or double fluted corrugated cardboard material, although the separator may comprise any suitable material including foam, paper foam, plastic, polyethylene foam, packing foam, styrene-butadiene block copolymers (e.g., SBS), or plastic. 
     Referring now to  FIG.  1   , an exemplary prior art shipping container  100  includes a bottom packaging component  102  having a plurality of concave receptacles  104  for receiving a plurality of respective bottles  106  therein. The bottom component  102  may also include a top surface  108  against which a bottom surface of a corresponding cap component (not shown in  FIG.  1   ) is configured to abut. 
       FIG.  2    depicts an exemplary prior art packaging system  200  including a bottom component  202  and a top (cap) component  204  for securing the tops of the bottles therein. Due to various factors including differences in bottle sizes/heights and limitations in vacuum molding manufacturing, a gap  206  often results between a bottom surface  207  of top component  204  and a top surface  209  of bottom component  202 . Consequently, prior art packaging systems employ an interleaved spacer to fill the gap, as described below in conjunction with  FIG.  3   . 
     More particularly,  FIG.  3    is a perspective view of an exemplary prior art packaging system including a corrugated divider  300  disposed within the aforementioned gap  206  (See  FIG.  2   ), the divider including interleaved orthogonal vertical segments  302 ,  304  extending between adjacent bottles. 
     Referring now to  FIG.  4   , the present invention replaces the aforementioned three dimensional divider with a substantially planar (two dimensional) bottle separator  400 , the separator including a plurality expandable holes  402  for receiving bottle necks  404  therethrough. The bottles may be retained within an outer corrugated box  408  (or alternatively, in one of the other illustrated boxes such as the outer corrugated box of  FIG.  2    comprising items  202  and  204 ). In various embodiments, the separator may include any desired number of holes such as, for example, a regular arrangement of  2 ,  3 ,  4 ,  6 ,  8 ,  9 ,  12 ,  15 ,  16 ,  18 ,  21 , or  24  holes. As described in greater detail below, the holes may include perforated or pre-cut extensions which allow the holes to flare open when the increasing diameter (or other cross section) of a bottle is urged therethrough. 
       FIG.  5    is a side elevation view of the assembly of  FIG.  4   , further including an optional top component (cap)  502  including a plurality of concave (generally conical) segments  504  for receiving the bottle tops. The bottles may thus be received within a bottom component  506 , spaced apart from one another by a separator  508  in accordance with the present invention, and further secured by the cap  502 . 
       FIGS.  6    is a plan view of an exemplary separator  600  including a plurality of expandable bottle neck receptors (holes)  602 , one or more of which may be characterized by a through hole  604 , and an expandable circumferential component  606  surrounding the through hole. In the illustrated embodiment, the expandable circumferential component  606  includes a plurality (e.g., 3, 4, 5, 6, 8, 9, 10 or more) of (e.g., trapezoidal) segments  608  separated by perforated or pre-cut lines  610 . In addition, one or more segments  608  may include a creased, scored, or otherwise pre-folded pivot line  612  to facilitate the outward flaring of the segments  608  as a bottle neck passes through the receptor  602 . In an embodiment, the expandable circumferential component suitably exhibits rotational symmetry, regardless of the number of segments. 
       FIG.  7    is an edge view (also a cross-section view) of an exemplary separator  700  having a double flute configuration including a first fluted portion  702  and an adjacent, second fluted portion  704 . 
       FIGS.  8  and  9    are close up views of exemplary bottle neck receptors viewed from the top and bottom of the planar separator, respectively. Specifically,  FIG.  8    depicts a partially expanded receptor  800  viewed from the top of the planar separator, and  FIG.  9    depicts an unexpanded receptor  900  viewed from the bottom of the planar separator. 
     More particularly and with continued reference to  FIG.  8   , an exemplary segment  808  is bounded by respective cut lines  810 , bend (or pivot) line  812 , and a preferably arcuate edge  811  surrounding the hole  804 . When viewed from the top of the planar separator, the segments  808  bend upwardly along line  812  as the bottle neck (not shown in  FIG.  8   ; see  FIG.  4   ) is urged upwardly through the hole  804 . The edge  811  slides along the length of the bottle neck as the separator is (typically manually) urged downwardly over the bottle necks to expand the circumferential region  806  about an associated bottle. In an embodiment, line  812  also functions as a visual indicator of the orientation of the planar separator. That is, when the separator is viewed from the top, line  812  is visible; when viewed from the bottom, line  812  is not visible. In other embodiments, line  812  may comprise a textual, graphical, printed, embossed, or decal for indicating the top (as opposed to the bottom) of the planar separator. 
     Returning momentarily to  FIG.  9   , when viewed from the bottom of the planar separator, each segment  908  bends downwardly along line  912  as the bottle neck proceeds through the hole  904 . 
       FIG.  10    illustrates an exemplary separator  1002  including a plurality of expandable receptors  1004  configured to secure a plurality of bottles  1006  within an outer box or container in accordance with various embodiments. For clarity, the outer box is not shown in  FIG.  10   ; but see, for example: items  202  and  204  of  FIG.  2   ; item  408  in  FIG.  4   ; item  506  in FIG. and item  1404  in  FIG.  14   . A cap portion (not shown in  FIG.  10   ; but see, e.g., item  204  in  FIG.  2   ) may also be place on top of the bottles to further secure them within the shipping container, if desired. 
       FIG.  11    illustrates a first exemplary separator  1100  characterized by: a width dimension  1102  (in the range of 10 to 18 inches, and preferably about 14 7/16 inches); a length dimension  1104  (in the range of 14 to 22 inches, and preferably about 18 5/16 inches); a width border dimension  1106  (in the range of 1 to 4 inches, and preferably about 2 13/16 inches); a length border dimension  1108  (in the range of 1 to 4 inches, and preferably about 2 5/16 inches); a lengthwise receptor center-to-center dimension  1110  in the range of 2 to 6 inches, and preferably about 4¼ inches); a widthwise receptor center-to-center dimension  1112  in the range of 2 to 6 inches, and preferably about 4¼ inches); and a tangential receptor dimension  1114  in the range of 1 to 5 inches, and preferably about 2 15/16 inches). 
       FIG.  12    illustrates a second exemplary separator  1200  characterized by: a width dimension  1202  (in the range of 11 to 13 inches, and preferably about 13.3 inches); a length dimension  1204  (in the range of 20 to 28 inches, and preferably about 24.2 inches); a width border dimension  1220  (in the range of 1 to 4 inches, and preferably about 2.7 inches); a length border dimension  1212  (in the range of 1 to 4 inches, and preferably about 2.5 inches); a lengthwise receptor center-to-center dimension  1208  in the range of 2 to 6 inches, and preferably about 4.6 inches); a widthwise receptor center-to-center dimension  1220  in the range of 2 to 6 inches, and preferably about 3.9 inches); a right side lengthwise border dimension  1210  (in the range of 4 to 6 inches, and preferably about 5.3 inches); a hole dimension (e.g., diameter) in the range of 0 to 1 inch, and preferably about 0.5 inches); and a tangential receptor dimension  1218  in the range of 1 to 5 inches, and preferably about 3.1 inches). 
     In the illustrated embodiment in which a receptor comprises a plurality (e.g., 8) of folding segments, each segment comprises a circumferential dimension  1216  in the range of 20 to 90 degrees, and in the case of eight segments, approximately 45 degrees. An exemplary hole dimension  1214  may be in the range of 0 to 1 inch, and preferably about 0.5 inches. In an embodiment, a hole may be diminishingly small, as long as the cut lines defining the pivoting flaps extend substantially or all the way through the separator. By simply creasing or scoring, as opposed to cutting the flap pivot lines, the flap&#39;s resistance to further folding assists in restraining the bottles from lateral movement during shipment. 
     In an embodiment, the hole may be stamped, die cut, or otherwise formed in a way which produces a smooth internal edge to avoid scratching the bottle label. Alternatively or in addition to the foregoing, the internal edge of the hole may be smoothed, for example by de-burring, sanding, or through the use of a moving abrasive material in a subsequent processing step after forming the hole. The hole size may be a function of the bottle neck diameter. 
       FIG.  13    illustrates a third exemplary separator  1300  characterized by: a width dimension  1302  (in the range of 10 to 16 inches, and preferably about 13.3 inches); a length dimension  1304  (in the range of 14 to 22 inches, and preferably about 18.9 inches); a width border dimension  1308  (in the range of 2.5 to 3.5 inches, and preferably about 2.7 inches); a length border dimension  1310  (in the range of 1 to 4 inches, and preferably about 2.56 inches); a lengthwise receptor center-to-center dimension  1312  in the range of 2 to 6 inches, and preferably about 4.6 inches); a widthwise receptor center-to-center dimension  1306  in the range of 2 to 6 inches, and preferably about 3.9 or about 4.2 inches); and a tangential receptor dimension  1314  in the range of 2.5 to 3.5 inches, and preferably about 3.1 inches). 
     The separator may comprise single or double walled corrugated cardboard, with an edge crush test (ECT) strength in the range of 26 to 56, and preferably about 32, and/or a Mullen burst strength in the range of 150 to 350 pounds, and preferably about 200 pounds. 
     Those skilled in the art will appreciate that any combination or sub-combination of dimensions described in conjunction with  FIGS.  11 - 13    may be embodied in a separator according to the present invention. 
     The separator may employ any desired fluting configuration depending on size, weight, and other relevant design parameters. By way of non-limiting example, an E flute may be used for a 4 pack; B flute for a 6 pack; and a C flute with a 12 pack. In addition, any suitable material and/or any configuration of that or those materials may be employed which satisfy the 3A and 5A drop test ISTA (International Safe Transit Association) protocols. Moreover, regular and irregular hole spacing may be employed to accommodate homogeneous and heterogeneous bottle combinations (to facilitate mixing-and-matching of different bottle sizes and shapes). 
     The separator may be constructed of any suitable material using any suitable manufacturing method. In the case of a fluted cardboard separator, a die on a die cut machine may be urged downwardly from above to cut the top surface of the planar sheet thereby forming the lines between adjacent folding flaps; the die cut machine may also be configured to (e.g., simultaneously) score the pivot (pre-fold) lines associated with the flaps. 
     Referring now to  FIG.  14   , an alternate embodiment includes a two-tiered separator assembly  1400  for securing one or more wine bottles  1402  within a base component  1404 . More particularly, the two-tiered separator assembly  1400  includes a first planar portion  1406  and a second planar portion  1408  folded upon each other about a connecting joint  1410  such as a folding hinge. As described in greater detail below, the first planar portion  1406  preferably includes a plurality of (e.g., circular) cut-outs  1412  for receiving a bottle; second planar portion  1408  preferably includes a plurality of downwardly foldable flaps (not shown in  FIG.  14   ; see  FIGS.  15  and  16   ) for stabilizing the bottom of the bottle. The first and second planar portions  1406 ,  1408  may comprise single or double fluted corrugate, or any other suitable material as contemplated herein. 
       FIG.  15    is a perspective view of an exemplary two-tiered separator assembly  1500  including a top planar component  1501  having a plurality of (e.g., circular) cut-outs  1503 , and a bottom planar component (substantially hidden from view in  FIG.  15   ) having a plurality of flap assemblies including a first assembly  1502  showing the flaps in a closed position and a second assembly  1504  showing the flaps in the downwardly extended position. The top and bottom planar component are suitably hingedly connected, for example along a perforated, scored, and/or creased binding  1510 . A fastener  1506  may be employed to retain the assembly in the folded position shown; that is, to maintain axial alignment of the cut-outs  1503  relative to their corresponding flap assemblies  1502 ,  1504 . Although the fastener  1506  is depicted as a foldable tab inserted into a rectangular docking port, those skilled in the art will appreciate that any suitable mechanism for (e.g., releasably) securing the top and bottom planar components together will suffice. 
     Referring now to  FIG.  16   , an exemplary two tiered separator assembly  1600  is shown in the unfolded (planar) position. Two tiered separator assembly  1600  is characterized by a lengthwise dimension  1602  (e.g., in the range of 24 to 30 inches, and preferably about 27 inches; and a width dimension  1604  (e.g., in the range of 16 to 22 inches, and preferably about 18.9 inches). 
     With continued reference to  FIG.  16   , the assembly includes a top planar component  1622  including a plurality of cut-outs  1610 , and a bottom planar component  1624  including a plurality of flap assemblies  1612 . In an embodiment, each flap assembly includes a plurality of substantially triangular flaps  1614  bounded by cut lines  1616  and pivotable (bendable) about a pivot line  1611 . The top and bottom planar components  1622 ,  1624  may be foldable about a hinge  1626 , as described above. When the top and bottom components are folded upon (and hence parallel to) each other, one or more tabs  1606  may be pressed into a corresponding dock  1608  to maintain the assembly in the folded over condition. 
       FIG.  17    is a side elevation view of the assembly in  FIG.  10   , further including an optional top component (cap)  502  including a plurality of concave (generally conical) segments  504  for receiving the bottle tops, where the bottles are received within a bottom component  506 . A visual indicia of orientation  1704  is provided. The assembly, top component  502 , and the bottom component  506  are placed within a corrugated outer box  1702 . 
     While the present invention has been described in the context of wine bottles, it will be appreciated that the invention is not so limited. For example, the separator may be used for any fragile items which include an upwardly extending neck portion such as ceramic or other compositions. Moreover, the various geometric features and dimensions may be adjusted to accommodate additional applications based on the teachings of the present invention. 
     A shipping container is provided, comprising: a vacuum molded base component having a plurality of cylindrical concave columns within which respective bottles are received; a substantially planar corrugated separator sheet having a plurality of receptors aligned with the axes of the columns and configured to slidably receive respective bottle necks associated with the bottles; a vacuum molded cap component for receiving the bottle necks therewithin; and an outer corrugated box within which the bottles, base component, separator, cap component components are securely disposed. 
     In an embodiment, the separator comprises a double fluted structure. 
     In an embodiment, at least one of the receptors comprises a through hole surrounded by an expandable circumferential component. 
     In an embodiment, the expandable circumferential component comprises a plurality of segments separated by pre-cut lines. 
     In an embodiment, the expandable circumferential component suitably exhibits rotational symmetry. 
     In an embodiment, the expandable circumferential component further comprises a pivot line; and at least one segment is configured to bend about the pivot line to facilitate the outward flaring of the segment as a bottle neck passes through the associated receptor. 
     In an embodiment, the pivot line comprises at least one of a creased line, a scored line, and a pre-folded line on an upper surface of the separator. 
     In an embodiment, the separator includes an even number of segments. 
     In an embodiment, the separator comprises visual indicia of orientation. 
     In an embodiment, the visual indicia of orientation comprises one of a textual and graphical orientation instruction. 
     In an embodiment, the visual indicia of orientation comprises one of a printed, embossed, and decal applied to a surface of a top surface of the separator. 
     A shipping container is provided, the shipping container being of the type including a vacuum molded base component having a plurality of cylindrical concave columns within which bottom portions of bottles are received, and a vacuum molded cap component within which top portions of the bottles are received. In an embodiment, the shipping container further includes a substantially planar separator sheet having a plurality of receptors aligned with the axes of the bottles and configured to slidably receive respective bottle necks therethrough. 
     In an embodiment, at least one of the receptors comprises: a central through hole; and an expandable region circumferentially disposed about the through hole. 
     In an embodiment, the expandable region comprises a plurality of flaps configured to bend about respective pivot lines in response to a bottle neck passing therethrough. 
     In an embodiment, the plurality of flaps are bounded by die cut lines. 
     In an embodiment, the central hole comprises a diameter of approximately 0.5 inches; and the expandable region is characterized by a tangential dimension in the range of about 2 to 4 inches. 
     In an embodiment, the die cut lines extend through the plane of the separator; and the pivot lines do not extend through the plane of the separator. 
     In an embodiment, the separator comprises a rectangular matrix of receptors spaced apart from each other by a distance in the range of 3 to 4 inches. 
     A method of packaging bottles of the type including a bottom portion and a neck is provided. The method includes: placing the bottom portions into a base component having a plurality of concave columns within which the bottom portions are received; sliding a substantially planar separator sheet over the bottle necks; placing a cap component over the bottles, the cap component comprising a plurality of recesses within which respective necks are received; and placing the assembled base component, bottles, separator sheet, and cap component into a box. 
     In an embodiment, the separator sheet comprises a plurality of holes each surrounded by foldable flaps bounded by preformed fold lines. 
     As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations, nor is it intended to be construed as a model that must be literally duplicated. 
     While the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing various embodiments of the invention, it should be appreciated that the particular embodiments described above are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. To the contrary, various changes may be made in the function and arrangement of elements described without departing from the scope of the invention.