PUTTING THE PLANET FIRST WITH

Sustainable paper honeycomb packaging

Paper honeycomb packaging is protective packaging built from a honeycomb of recycled paper cells bonded between paper facings. It is rigid and light, and it recycles in standard paper streams. Envirolite® is Dufaylite’s paper honeycomb packaging: engineered inserts, edge protectors, pallets and layer pads that replace polystyrene (EPS) and foam, made in St Neots by the only UK manufacturer of paper honeycomb.

Dufaylite is the only UK manufacturer of paper honeycomb, and the only paper honeycomb provider in the world to hold the BRCGS AA Global Food Safety Standard. Dufaylite is certified Carbon Neutral Britain™ and FSC® (C186880).

Envirolite®: sustainable paper honeycomb packaging

Envirolite® is engineered, not off-the-shelf. The core is 100% recycled paper; the facings are recycled paper or kraft, depending on the application. We make it in 8, 15, 27 and 47mm cell sizes and thicknesses from 6mm to 100mm, then cut and build it around your product, so the protection is tuned to your actual drop and stacking loads. See how paper honeycomb is made.

100% recycled and recyclable paper:
Keeping it green and in the loop.

6.4x less CO₂ than polystyrene:
A lighter footprint for a brighter future.

Why choose Envirolite®?

Give your customers what they want with sustainable packaging solutions that don’t compromise on quality.

Support a circular economy with fully recyclable materials.

Bespoke solutions tailored to your specific needs.

recycled, 100% recyclable.

less CO2 than polystyrene.

of consumers avoid brands with poor environmental practices.

What is paper honeycomb board used for?

Products made with Envirolite®

With Envirolite®, we offer a diverse range of paper honeycomb packaging solutions, from corner edge protection and void fillers to cardboard pallets, layer pads and bespoke packaging solutions. Industries such as food and drink, furniture, electronics, and logistics all choose our materials.

What we supply

Product	What it does	Sizes and formats	More
Protective inserts	Hold and cushion the product inside the box; replace moulded EPS	Engineered to your product, 6–100mm thick	Bespoke packaging
Corner and edge protectors	Protect corners and edges in the box and on the pallet	Made to your product’s dimensions	Corner protection
Void fill	Fills large spaces in heavy packs with less material	Bespoke	Void fill
Paper honeycomb pallets	One-way pallets for export and distribution	1200 × 1000mm, 1200 × 800mm, or bespoke to the load; ISPM15 exempt	Pallets
Layer pads (pallet separators)	Separate and stabilise each layer of a load	Made to your pallet footprint	Transit packaging
Food box thermal liners	Keep chilled deliveries cold; kerbside recyclable	Made to your box	Food packaging
Paper honeycomb core and board	Plain core or board sheets for converters to cut and use themselves	8, 15, 27 or 47mm cells; 6–100mm thick	Contact us

Your UK EPS alternative packaging supplier

An EPS alternative packaging supplier should replace polystyrene with a recyclable material, carry a lower EPR liability, and protect your product just as well. Dufaylite makes the material itself — we are the only UK manufacturer of paper honeycomb — and engineers bespoke Envirolite® inserts to replace EPS, backed by BRCGS AA food safety and Carbon Neutral Britain™ certification.

Most teams searching for an EPS alternative packaging supplier end up with a converter or an importer — a business that buys honeycomb core in and cuts it, or ships finished board from Europe. Dufaylite is different. We make the paper honeycomb here in St Neots, then engineer it around your product. That means shorter lead times, UK supply-chain security, and an in-house lab team that solves your protection problem rather than selling you a stock part.

What to look for in an EPS alternative packaging supplier

Switching from polystyrene is an engineering decision as much as a procurement one. Use these criteria to shortlist any polystyrene replacement packaging supplier — and see how Dufaylite maps against each.

What to look for	Why it matters	Dufaylite
Manufactures the material (not just converts or imports)	Control of quality, lead time and bespoke specification	The only UK manufacturer of paper honeycomb
BRCGS AA food safety	Needed for food-contact and audited supply chains	The only honeycomb provider in the world with BRCGS AA
Genuine recyclability & lower EPR rating	Kerbside recycling and lower modulated EPR fees	100% recycled paper core, kerbside recyclable
Independently verified carbon data	Evidence for ESG reporting, not vague claims	Independent CarbonQuota study of our food box thermal liner
Bespoke engineering & in-house lab	Like-for-like protection for your exact product	In-house lab; every solution engineered to spec
UK manufacturing & short lead times	Supply security and lower transport carbon	Made and cut in St Neots, Cambridgeshire

Is paper honeycomb a like-for-like EPS replacement?

In most applications, yes. Engineered paper honeycomb matches or exceeds EPS cushioning for its intended load, and it can be cut and built up into the same engineered shapes as a polystyrene insert. The core is 100% recycled paper; the facings are recycled paper or kraft, depending on the application. Our lab tests each solution against your product before you switch — there is a proven way to replace polystyrene without compromising protection.

The commercial case for switching supplier

Paper enters standard recycling streams, so Envirolite® carries a lower EPR liability than EPS under the modulated fees of the UK’s Extended Producer Responsibility scheme, and there is no plastic packaging tax on a paper insert. For procurement, the total cost of ownership — fees, disposal and customer expectation — increasingly favours paper over polystyrene.

The proof is independently held: BRCGS AA food safety, Carbon Neutral Britain™, FSC certified (C186880), and an independent CarbonQuota carbon footprint study of our food box thermal liner. Note that Dufaylite manufactures structural paper honeycomb panels and engineered inserts — not the roll-format honeycomb wrap paper used for e-commerce void fill, which is a different product made by other suppliers.

Ready to switch? Get a quote or request samples from the UK’s only paper honeycomb manufacturer.

Let’s make the change together

Step 1

Step 2

Step 3

Step 4

Step 5

STEP 1

Let’s chat
First things first – let’s have a good old-fashioned chat. We’ll hop on a call to really get to know what you need, answer all your questions, and start brainstorming the perfect sustainable packaging solution.

STEP 2

Onsite visit
Next up, one of the ‘Dufayliters’ will pay a visit to your site to get a close-up look at the operation. This hands-on approach helps us craft to your specific needs. It’s not just about seeing the space; it’s about understanding how the design will work in the actual environment. Everything from factory space to the speed of the packing process and the movement of goods is considered. This attention to detail ensures that the design works seamlessly for everyone throughout the business.

STEP 3

Collaborate in our design lab
Now it’s time to bring your product and your team over to our design lab. We’ll roll up our sleeves and dive into a collaborative session, discussing the project, technicalities and requirements to create the ideal solution. Together, we’ll develop the concept and whip up prototypes that hit the mark.

STEP 4

Pricing and delivery
From there, we’ll work out the pricing and make sure we’ve got the most cost-effective, whole-project solution for you. We’ll keep the bigger picture in mind, ensuring everything is on point, from budget to delivery.

STEP 5

Solutions that work
Finally, we’ll deliver a custom, sustainable paper honeycomb solution that protects the planet. With us, it’s not just about meeting a requirement – it’s about embracing a whole new way of doing things.

Ready to master Envirolite®?

Curious to learn more about our design lab for packaging? Head to our Design Lab page to see how we can help you take your packaging design skills to the next level. We’re excited to work with you and bring your ideas to life.

What you can expect from us…

SUSTAINABILITY AT HEART
We’re all about keeping things green. Our packaging is made from 100% recycled and recyclable materials, so you’re not just protecting your products – you’re also protecting the planet. Let’s work together to smash those net zero targets!

INNOVATION IN EVERY FIBRE
We don’t do ‘one-size-fits-all’. Our design lab channels new ideas, crafting clever packaging solutions that are as innovative as they are sustainable. Expect the unexpected, because we love a good challenge.

BESPOKE SERVICE
Your needs are unique, and so are our solutions. We work closely with you to create custom honeycomb designs that fit your product, business, and budget perfectly. Every creation is tailored, sustainable, and built to deliver.

UNWAVERING QUALITY
Quality is in our DNA. Every product we make meets the highest standards. Because when it comes to protecting your goods and the environment, there’s no room for compromise.

EXPERTISE YOU CAN TRUST
With more than 70 years of experience under our belt, we’ve seen it all and solved a lot. Whether it’s replacing polystyrene or navigating new sustainability regulations, we’ve got the know-how to guide you through it.

UK-BASED MANUFACTURING
Proudly made in the UK, our paper honeycomb is crafted under one roof for a smooth, reliable service. No long lead times, no complex logistics—just top-quality, British-made solutions delivered with care.

Frequently Asked Questions

How easy is paper honeycomb packaging to use?

Paper honeycomb packaging is crafted for simplicity, making the packaging process more efficient and straightforward. It incorporates eco-friendly materials into operations, reducing hassle while maximising impact. This approach not only enhances the packaging process but also supports sustainable practices, making it an effective choice for businesses committed to greener solutions.

What choices of bespoke sustainable packaging are available?

When it comes to bespoke sustainable packaging, paper honeycomb packaging is a versatile solution. Whether it’s tailoring the size, thickness, or design, paper honeycomb can be adapted to protect products effectively. This sustainable material provides strong, reliable protection and aligns with eco-friendly practices. By offering a bespoke approach, paper honeycomb packaging ensures that every detail is considered.

What are the minimum order quantities (MOQs)?

Minimum Order Quantities (MOQs) can vary based on the product type and customisation needs. The beauty of paper honeycomb is its versatility, allowing for flexibility in meeting different requirements. For specific details, it’s best to get in touch. Options can be tailored to suit various needs while staying committed to sustainability.

What are the lead times for paper honeycomb packaging?

Lead times for paper honeycomb packaging are typically around 4 weeks. However, there’s plenty of flexibility to meet specific deadlines. No unnecessary waiting – just a commitment to delivering on time.

What are the delivery charges for paper honeycomb packaging?

Delivery charges for paper honeycomb packaging depend on the order size and destination. For specific details, just get in touch, and the packaging will be delivered without a hitch.

Where can paper honeycomb samples be obtained?

Paper honeycomb samples are available upon request. It’s all about trying before committing – because seeing really is believing! This hands-on approach ensures the packaging meets all the needs before moving forward.

What are the thickness options for paper honeycomb board?

Paper honeycomb board comes in a range of thicknesses, from 6mm to 100mm. Whatever the requirements, there’s a perfect fit to meet your needs.

What are the strength capabilities of paper honeycomb board?

With its impressive strength, paper honeycomb board is a standout choice for sustainable packaging that doesn’t compromise on durability. In testing, a standard layer pad with a 15mm cell can support up to 25 tonnes per square metre. If even more strength is needed, the 8mm honeycomb board provides enhanced durability.

Can the density of paper honeycomb board be changed?

Yes, the density of paper honeycomb board can be adjusted to achieve different strength properties – whether it’s lightweight eco-friendly packaging or more robust recyclable materials needed. This flexibility ensures that the packaging not only performs effectively but also aligns perfectly with sustainability goals.

How can paper honeycomb replace polystyrene in packaging?

Paper honeycomb packaging eliminates the need for polystyrene in inside-the-box packaging, by redesigning with void fill, corner, and edge protection made from honeycomb board. It delivers the same protective qualities but is lightweight, sustainable, and fully recyclable. It significantly cuts down on plastic packaging waste, making it a choice that’s good for both the business and the environment.

Do the paper honeycomb cells change under high humidity?

Paper honeycomb products are built to handle normal humidity levels without any significant changes. They perform just as well in moist conditions, staying strong and reliable no matter the weather.

Does paper honeycomb packaging withstand multiple drops and vibrations?

Paper honeycomb packaging is engineered to handle multiple drops and vibrations. Its robust structure absorbs shocks and reduces the impact on packaged items, ensuring they stay secure no matter the journey. Honeycomb packaging is lightweight, making it easier and more cost-effective to transport while still providing the durability needed for safe delivery.

Would paper honeycomb packaging speed up or slow down the manufacturing process?

Paper honeycomb packaging can actually speed up the manufacturing process due to its ease of use and lightweight properties. By incorporating sustainable packaging like honeycomb, processes become more streamlined, enhancing both efficiency and sustainability. It’s where speed meets eco-friendliness, making operations smoother and greener.

How does paper honeycomb packaging help protect products from handling damage?

Paper honeycomb packaging acts like a protective shield, offering exceptional shock absorption and impact resistance to keep products safe from any bumps along the way. The real magic happens in the Dufaylite Design Lab for Packaging Designers. Spend a day there – bring a packaging challenge, meet a team of innovators, and dive into the design process. It’s an opportunity to see how it’s all made and even walk away with some samples. Turning packaging ideas into reality is a collaborative process, and it all starts with finding the perfect solution together!

What % of recyclable material does paper honeycomb packaging contain?

Most paper honeycomb packaging products are made from 100% recycled paper. For those heavy-duty jobs requiring a bit more strength, virgin fibre papers are used – but rest assured, all paper is sourced from FSC-certified forests. Plus, every bit of honeycomb packaging is 100% recyclable, keeping the circular economy spinning and helping to meet net zero targets. It’s sustainability without compromise!

Does paper honeycomb packaging comply with new packaging waste regulations?

Certainly! Paper honeycomb packaging is designed with both current and upcoming regulations in mind. Staying ahead of regulatory changes is a priority, ensuring that the packaging always meets the latest standards. Compliance is practically its middle name.

Is paper honeycomb packaging cost-effective compared to other sustainable packaging solutions?

Absolutely! Paper Honeycomb packaging is cost-effective, offering protection at competitive prices. Starting with a clear budget ensures the right material specifications are chosen, saving time and staying within financial limits. Honeycomb packaging often leads to savings in other areas, making it a smart choice when considering the bigger picture.

Are there any tooling costs involved in paper honeycomb packaging?

There are a variety of converting machines available to deliver all sorts of solutions. Tooling costs might come into play for bespoke projects, depending on the conversion process required. For specific details, just reach out, and everything can be broken down clearly.

Are there data sheets for paper honeycomb packaging?

Yes, data sheets are available! Product data sheets can be provided upon request and are also accessible on the website. Dive into the details whenever needed!

Does paper honeycomb support increasing 'board grade'?

It sure does! There’s support and solutions available to enhance the grade and performance of paper honeycomb boards. Just share what’s needed, and help will be on the way to take it up a notch.

What certifications standards align with paper honeycomb packaging?

Paper honeycomb packaging aligns with all the top standards. This includes ISO9001 for Quality, ISO 14001 for Environment, and ISO45001 for Health & Safety. But that’s not all – there’s also FSC certification for responsible sourcing and BRCGS certification for food safety. Need specifics? All the details can be provided.

Are paper honeycomb boards FSC certified?

Yes, paper honeycomb boards are FSC certified, ensuring the responsible sourcing of materials. The certificate number is C186880 – proof that sustainability is taken seriously at every step.

Is Dufaylite a carbon neutral organisation?

Dufaylite is proudly carbon neutral, meeting all the standards of the Carbon Neutral Britain Certification™. We’re all about action – measuring, calculating, and offsetting our carbon footprint through UK tree planting projects to give back to the planet. And we’re not stopping there! We’re already on the path to our next big goal: achieving net zero.

Want to keep up with our journey? Follow us on social media for the latest updates or pop over to our Dufaylite Sustainability page to learn more about our green credentials.

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