Honeycomb boardĀ (aka paper honeycomb board / honeycomb core board) is a sandwich structure made with kraft/testliner facingsĀ and a hexagonal paper honeycomb coreĀ bonded with adhesive. The honeycomb geometry delivers exceptional strength-to-weight, flat crush resistance, and cushioning, making it a fast-growing choice for protective and display packaging, pallets, and furniture cores.
Key Advantages
High strength, low weight:Ā Replaces portions of wood or foams while cutting weight and freight.
Cushioning & shock absorption:Ā Core dissipates impact and vibration, reducing transit damage.
Configurable:Ā Thickness, cell size, and liner gsm can be tuned for strength, cost, and appearance.
Easy to convert:Ā Cut, slot, V-groove, crease, window, laminate, glueĀ into corners, edge guards, sleeves, pads, and pallet components.
Sustainable:Ā Fiber-based, widely recyclable, available with FSCĀ®Ā options; supports plastic reduction goals.
Specs & Structure (Selection Guide)
Thickness:Ā Commonly 10ā60 mm; heavy-duty pads/pallet decks 80ā100 mm.
Cell size:Ā ~10ā30 mm. Smaller cellsĀ ā flatter surface & higher compressive strength; larger cellsĀ ā lower cost & softer cushioning.
Facings:Ā Kraft/testliner by default; white linersĀ for premium look; add moisture-resistant coatingsĀ for humid lanes/cold chain.
Adhesives:Ā Starch or PVA systems; specify enhanced moisture resistance if required.
Quick pick:
E-commerce appliances/furniture buffers:Ā 20ā40 mm.
Pallets & load decks:Ā 40ā80 mm.
Door/furniture cores:Ā 10ā30 mmĀ prioritizing light weight.
Common Applications
Transport & warehousing:Ā Paper pallets, deck boards, skid feet, layer pads, separators, edge/angle protectorsāalternatives to wooden or plastic components.
In-pack protection:Ā Custom cushions for appliances, furniture, sanitary ware, glass/stone, and metal parts.
Display & construction:Ā POP displays, panels, temporary buildsālight, flat, and easy to assemble.
Door/furniture cores:Ā Thick, rigid feel with major weight and cost savings.
Converting & Finishing
Forming:Ā V-groove + foldĀ to create clean corners; supports both large radii and sharp edges.
Surfaces:Ā Laminate kraft, whiteboard, or specialty papers; for exposed faces, add varnish/anti-scuff film.
Joining:Ā Hot-melt, PVA/white glue, or stapling; increase bond area for heavy-load zones.
Moisture & edges:Ā Use barrier coatings/filmsĀ for humid routes; protect edges with edge tape/angle boards.
Performance & Testing
Validate flat compression, edge/load support, drop/impact, and wet-strength retention.
For pallets/platforms, test static/dynamic loadĀ and racking/BCT; assess creepĀ and cyclic compressionĀ for long storage.
For cold chain or ocean freight, run high-humidity/low-temperature cyclesĀ and peel/bond tests.
Limitations & How to Mitigate
Lower puncture resistance than wood/plastic:Ā Add hard facingsĀ or reinforced corner/edge piecesĀ for sharp parts.
Humidity sensitivity:Ā Specify moisture-resistant liners/adhesivesĀ and protect during storage/transport (shrink/PE bags).
Point-load sensitivity:Ā Distribute loadĀ with caps or spreader plates; avoid small hard contact points.
Replacement & Cost-Down Ideas
Replace EPS/EPE foam:Ā Honeycomb edge/angle profiles + linersĀ for recyclable cushioning.
Replace wood crate elements:Ā Honeycomb pads, ribs, and feetĀ with heavy kraft facings for weight and labor savings.
Paper pallets:Ā Honeycomb deck + paper feet = ISPM-15 exempt, light, and export-friendly.
Sustainability & Compliance
Fiber-based and widely recyclable, with FSCĀ®Ā and recycled-content options available. For food/medical proximity, confirm odor/migrationĀ performance and add functional barriersĀ where regulations require.