Paper cushioning is available in two forms. The first is pre-formed, where the material is manufactured at a factory, packed into cartons, and shipped to the packing operation. The second is on-site, where the material is produced at the packing bench from paper rolls.
Both forms use paper. The difference is where the forming happens, and that difference changes the storage profile, the flexibility, and the cost per parcel.
Storage
Pre-formed paper cushioning arrives as finished material. It takes up warehouse space from delivery to use, and the space is proportional to the volume of material ordered. A bulk order to get a volume discount means a large volume of finished material sitting in storage.
On-site production stores paper rolls rather than finished cushioning. Paper rolls are dense and stack compactly. 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. The storage area for the equivalent protection capacity is smaller.
Flexibility
Pre-formed cushioning comes in fixed formats. The operation orders a specific size and shape, and the material arrives in that format. If the product mix changes, the operation may need a different format, and the pre-formed material that was ordered for the old mix may not fit the new one.
On-site production adapts to the product mix. Die-cutting width is adjustable between 200 and 500mm, and die-cutting speed is adjustable between 5 and 18 m/min. The operator can match the output to the carton and the product, which means the material fits the actual order rather than the format that was ordered in advance.
Cost per Parcel
The cost per parcel depends on the unit cost of the material and the amount used per parcel. Pre-formed cushioning has a unit cost that includes the manufacturer's equipment depreciation, labor, margin, and logistics. On-site production has a unit cost that includes the paper roll and the electricity.
The amount used per parcel depends on how well the material matches the product. Pre-formed material in a fixed format may be too large or too small for a given parcel, which means the operator uses more or less than necessary. On-site production matches the material to the parcel, which means the amount used is closer to the amount required.
What On-Site Production Requires
On-site production requires a machine. A compact machine with a footprint of just over 1 cubic meter, dimensions around 950x1150x1260mm and net weight near 502kg, fits beside a standard bench. It runs on standard AC220V/50HZ at 1.5kW total power, with no compressor, heating element, or adhesive system, which means it can be installed without electrical work.
The machine requires an operator. The operator produces the material as part of packing the parcel, which means the production step is integrated into the packing workflow rather than added to it.
What Pre-Formed Production Requires
Pre-formed production requires a supplier. The operation places an order, the supplier manufactures and ships the material, and the operation stores it until it is used. The supplier relationship adds a lead time and a dependency that on-site production does not have.
The pre-formed model also requires a forecast. The operation has to estimate the volume and the format before placing the order. The forecast is a guess, and the guess is often wrong in both directions.
Which Model Fits
Pre-formed cushioning fits operations with stable product mixes and predictable volumes. The forecast is reliable, and the storage burden is manageable.
On-site production fits operations with mixed product ranges, seasonal volumes, or limited storage space. The machine adapts to the changes, and the storage burden is smaller.
The output from a honeycomb paper machine is biodegradable packaging and degradable packing material, a practical alternative to plastic packing materials, and it supports reuse cartons and paper recycling. A die that lasts about 1.0~1.3 million meters keeps the cells uniform across the entire run.