Flexi Hex Air Sleeves, Caps & Wraps

How Flexi-Hex® Air Sleeves, Caps and Wraps Work Together

Flexi-Hex® Air Sleeves, Caps and the Wraps are designed to protect fragile items in transit using paper-based, plastic-free materials. The three product types serve different roles: Air Sleeves wrap the body of an item with an expandable honeycomb tissue paper sleeve, Caps cover the top and base with a moulded paper pulp shell, and the Wrap is a  paper pulp strip  that wraps around a sleeved bottle or other product and holds everything in place inside the outer packaging.

Used together, they form a complete system that cushions the bottle, reduces movement and absorbs the normal bumps and drops of transit. Each product is also useful on its own. The Air Sleeves in particular are well suited to smaller fragile items where a full bottle kit may not be needed.

Flexi-Hex® Air Sleeves

Flexi-Hex® Air Sleeves are Kraft lightweight honeycomb sleeves made from high-quality tissue paper. The hexagonal cell structure opens out as you slide the item in and grips it from all sides, providing cushioned protection without adding significant weight to the package. The lighter construction makes them a practical alternative to bubble wrap for smaller fragile items such as cosmetic bottles, candles, glass jars, electronic devices and small homewares.

Air Sleeves are stocked in four lengths to suit different item sizes:

Flexi-Hex® Air 10cm Sleeve for small fragile items such as sample pots, travel-size cosmetics and small jars.

Flexi-Hex® Air 20cm Sleeve for standard-size jars, candles and tumblers.

Flexi-Hex® Air 25cm Sleeve for taller jars, small bottles and cosmetic packaging.

Flexi-Hex® Air 35cm Sleeve for larger items, including taller bottles, vases and longer fragile pieces.

All Air Sleeve sizes are packed in 100s and supplied flat-packed to keep storage compact in your packing area.

Flexi-Hex® Caps

Flexi-Hex® Caps are moulded cardboard  covers that sit over the top or base of a bottle, jar or fragile item to protect the ends from drops and knocks. The caps are made from over 85% recycled paper pulp, and are completely plastic free, recyclable through standard household recycling, biodegradable and compostable. They carry the same eco credentials as the rest of the Flexi-Hex® range.

Caps are designed to be used as part of a complete protective system alongside Flexi-Hex® Sleeves and Wrap. Used together, the sleeve covers the body of the item, the cap covers the top and base, and the wrap forms an outer layer that holds the package in place. Stocked in five diameters to suit different bottle and container sizes:

Flexi-Hex® Cap 100mm, 110mm, 120mm, 130mm and 140mm. Choose the cap size that is approximately 10mm larger than the product you are protecting  . All five sizes are packed in 100s.

Flexi-Hex®Wrap

The Flexi-Hex® Wrap is a  paper pulp strip  that wraps around a sleeved bottle or other cylindrical item and holds it securely in place inside the outer box. Like the Caps, the Wrap is made from over 85% recycled paper pulp. It is plastic free, recyclable, biodegradable and compostable.

The wrap is designed to work as the third layer in the complete protective system: a Flexi-Hex® Sleeve grips the body of the item, a Cap covers the top, and the Wrap wraps around everything to lock the package in place. Self adhesive labels are supplied to hold the wrap in place around the product The wrap is particularly useful for businesses shipping packages where the outer box is slightly larger than the bottle or product alone, as it fills the void and prevents the bottle or product from moving in transit. Packed in 100s.

Common Uses for Plastic-Free Protective Packaging

The smaller-format Flexi-Hex® range is used across a wide range of fragile-product sectors. Cosmetic and skincare brands use the Air Sleeves to protect glass bottles, jars and travel-size containers in transit. Candle makers use them around glass candle vessels, often pairing them with Caps to protect the rim and lid. Easter egg producers, chocolatiers and confectioners use the Caps and Wrap to give moulded protection to fragile or irregular shapes.

Drinks brands and online retailers shipping single bottles often use the full sleeve, cap and wrap ensemble for a complete plastic-free package, especially for premium products where the unboxing experience is part of the brand. The Air Sleeve range is also used for non-bottle products such as homewares, ceramics, small electronics and giftware where the lighter tissue paper honeycomb is enough to cushion the item.

Flexi-Hex® Air Sleeves, Caps and Wraps FAQs

Q: What is the difference between Flexi-Hex® Air Sleeves and standard Flexi-Hex® Bottle Sleeves?

Air Sleeves use a lighter tissue paper construction, while the standard Bottle Sleeves use a heavier honeycomb paper. Both have the expandable hexagonal structure, so they grip and cushion the item the same way. Air Sleeves come in four lengths (10cm, 20cm, 25cm, 35cm) and are better suited to smaller, lighter fragile items such as cosmetics, candles and small jars. The standard Bottle Sleeves are the right choice for full-size 750ml wine, spirit and beer bottles.

Q: What are Flexi-Hex® Caps made from?

Flexi-Hex® Caps are made from moulded cardboard  (over 85% recycled). The pulp is moulded into a cap shape that sits over the top or base of a bottle or product. They are plastic free, recyclable, biodegradable and compostable, the same as the rest of the Flexi-Hex® range.

Q: Do I need to use Air Sleeves, Caps and the Wrap together?

No. Each product can be used on its own or as part of the kit. Together these items are ideal for wrapping fragile objects such as Easter Eggs, candles or jars. The standard combination for shipping a single item is a Flexi-Hex® AirSleeve plus a Cap plus the Wrap, which forms a complete protective system. But for smaller items, an Air Sleeve on its own is often enough.

Q: What size cap do I need?

Choose the cap diameter that exceeds the outside diameter of your item by 10mm. Caps are stocked in 100mm, 110mm, 120mm, 130mm and 140mm. If you are not sure which size suits, request a sample first to test the fit before ordering in bulk.

Why Buy Flexi-Hex® Air Sleeves, Caps and Wraps from Forms Plus?

Forms Plus have supported businesses with their printing and packaging requirements since 1981 and are close neighbours to Flexi-Hex® in Cornwall. We stock the full Flexi-Hex® range, including all four Air Sleeve lengths, all five Cap diameters and the Bottle Wrap, with competitive pricing, in stock for fast despatch.

Free samples are available on selected products so you can test the fit and quality before ordering in bulk. If you are not sure which combination of sleeve, cap and wrap suits your products, our team can advise.

Request a Free Sample or Contact Our Team if you would like help choosing the right Flexi-Hex® product for your needs.