Palletized shipments are common in B2B logistics. Products are stacked on a pallet, wrapped in stretch film, and shipped as a unit. The cushioning requirements for a pallet are different from the cushioning requirements for an individual parcel.
A pallet experiences different stresses. The product at the bottom of the stack carries the weight of everything above it. The edges of the pallet are vulnerable to impact from forklifts and from adjacent pallets. The layers between products need to prevent abrasion as the products settle against each other during transit.
What a Pallet Requires
The first requirement is interlayer cushioning. When products are stacked, the layer above applies pressure to the layer below. Without cushioning between layers, the products abrade against each other, and the abrasion shows up as scratches or scuffs.
The second requirement is edge protection. The edges of the pallet are the most vulnerable part. A forklift that clips the edge can damage the product on the corner. Cushioning on the edges absorbs that impact.
The third requirement is corner protection. The corners of the pallet are the most vulnerable part of the edge. Cushioning on the corners keeps the stretch film from cutting into the product and absorbs impact from the sides.
How Honeycomb Paper Handles These Requirements
Honeycomb paper is formable, which means the operator can shape it into layers, edges, and corners. A flat sheet of honeycomb paper placed between layers provides interlayer cushioning. A folded strip of honeycomb paper placed on the edge provides edge protection. A folded corner piece provides corner protection.
The honeycomb structure disperses impact under load, which is what makes it useful for edge and corner protection. The material also resists compression, which means it maintains its thickness under the weight of the stack.
What the Machine Needs to Produce
A honeycomb paper machine produces the material in flat sheets. Die-cutting width is adjustable between 200 and 500mm, so the operator can produce sheets that match the pallet dimensions. Die-cutting speed is adjustable between 5 and 18 m/min, so the operator can produce the material at the pace the pallet packing requires.
The operator shapes the sheets into the required forms. A flat sheet for the interlayer. A folded strip for the edge. A folded piece for the corner. The material holds its shape once formed, which means the protection stays in place during handling.
Why On-Demand Production Fits Pallet Packing
Pallet packing is often done in batches. A batch of pallets is packed, and then there is a gap before the next batch. During the gap, purchased cushioning material sits in storage.
A honeycomb paper machine produces the material when it is needed. Suitable paper is ≤80gsm, and both virgin kraft paper and recycled paper work. A paper roll length of about 1700m, with a maximum unwind diameter of 500mm and a paper core inner diameter of 75mm, supports a long production run before the roll needs to be changed.
What the Machine Delivers
A honeycomb paper machine placed in the pallet packing area delivers cushioning that can be shaped for layers, edges, and corners. Power requirements are modest: 1.5kW total power at AC220V/50HZ, with no compressor, heating element, or adhesive system. A compact footprint of just over 1 cubic meter, dimensions around 950x1150x1260mm and net weight near 502kg, means the machine can sit near the pallet packing area. A die that lasts about 1.0~1.3 million meters keeps the cells uniform across the entire run.
The output is biodegradable packaging and degradable packing material, a practical alternative to plastic packing materials, and it supports reuse cartons and paper recycling. For palletized shipments, that combination protects the product and simplifies the disposal.