I should write an article on packing beer in luggage, based on all of my trips. I've only lost 2 beers in my ~500 beers I've flown with. One was way back when and a shitty packing job (in a poorly-packed cardboard box), and the other was to the cap popping off.
My cheat sheet, if you follow all of the steps, it is surely overkill, but there is nothing more annoying than arriving in customs with a bag that smells like Nash's Doppelganger (
http://hartandthistle.blogspot.com/2010 ... moked.html" onclick="window.open(this.href);return false;), picking out shards of glass from your underwear.
Luggage choice:

- I use hard-sided nesting bags:
Carribean Joe 3-piece spinners. These are not the very tough Pelican cases (out of my price range, unless I become a beer/wine mule for an eccentric millionaire), but serve me well. Light and maneuverable, which helps for all of the flying I do.
- I limit my clothes/stuff to what will fit in the middle-sized bag, but then put that into the large bag: 2 for the price of one. Helps to distribute the weight (for me and the luggage handlers).
- These bags open like a clamshell, the two halves are the same. At first I thought that was bad, but now I realize that is perfect for beer preservation.
Packing technique:
- I tape each bottle closed with packing or duct tape. Don't want to be poppin' corks/caps till we get home! Just a small piece keeping the cap on tight is sufficient.
- I put each bottle into a ziplock or other bag taped/zip-tied up. In case of popping, want to reduce the mess.
- Each bottle gets at least a pair of socks (I have big feet, so no problem fitting bombers in them), maybe bubble wrap if I bought it/brought it with me. No bare glass visible.
- I lay the luggage open flat, and put down a layer of tough but soft clothes/stuff (jeans, maybe newspapers, books I've picked up). Remember to protect all sides of the luggage (bottom, top, all four sides).
- Then I start putting in the bottles. I will wrap pairs/groups of three bottles together in shirts/shorts. Want to keep the bottles tightly packed. Biggest problem after luggage dropping is shifting of bottles around and breaking each other.
- I close up the luggage, give it a hard jostle to make sure I don't hear/feel anything move, then make sure its good on weight (thank you hotel gym scale!).
Good luck!