Dufaylite shipping layer pads
Layer pad packaging for shipping

Rethinking our approach to layer pads


Which material to use for layer pads has been a huge obstacle for packaging and shipping for years. Companies have been forced to either use timber sheeting, which is heavy and unwieldy, or use MDF which, frankly, is as good as rubbish.

The problem is that solid timber adds so much weight that you’re forced to include reinforcement – or simply have a height limit that’s much lower than it should be. Cardboard, on the other hand, is lightweight but sags significantly in between items. This means that, quite often, the stack ends up slanting anyway.

There are a lot of problems with layer pads.

So we set out to develop the perfect solution using our revolutionary honeycomb board. 

The perfect solution for layer pads

We realised that, using our honeycomb board, we could make extremely lightweight, strong layer pads for applications that would otherwise require heavy timber or multiple sheets of cardboard.

How? 

Well, our honeycomb pattern not only creates boards with a really impressive compression strength, but goes together to make a rigid board that’s significantly lighter than other options. 

This, essentially, means that you can stack heavier objects on more layers than you otherwise could.

It’s also able to account for irregularities in the shapes of goods. Let’s take the shape of Coca Cola bottles as an example. The thinner tops means that they’re much more likely to break at the top when stacked highly without any support. Even adding MDF doesn’t fully account for this as it’s not an entirely rigid surface.

Our layer pads create a rigid surface that spreads out the weight evenly. This stabilises the load and reduces the chance of either a stack tilting, or goods at the bottom breaking. 

It’s the perfect combination of a lightweight, more effective material that’s also made from recycled material – and is itself recyclable.

Layer pads for all applications

The other significant benefit of our material is that, because it’s made out of paper, we’re able to easily cut sections out to accommodate irregularly-shaped objects. Let’s take a standard juice carton as an example. The odd tab at the top often makes stacking difficult without crumpling the tops of cartons.

With our honeycomb layer pads, however, we can cut out the exact shape of the cartons in order to accommodate the shape and spread the weight evenly, thus enabling stacking where it wasn’t previously possible.

Layer pads for all applications

The other benefit of paper is that we can part cut and crush segments rather than cut and take out segments. This means we can create a cushioning effect around objects. A win, win, win, if you ask us!

Easier to wrap

Most layer pads come with sharp corners, because when working with timber or MDF it’s easier to simply rip sheets into squares.

We chamfer the edges of our layer pads as well as round the corners, meaning that you don’t have to worry about package wrap splitting if you haven’t used corner pads.

It’s a hallmark of how we like to solve problems: simple, elegant solutions that save on materials, increase potential, and remain environmentally friendly.

Layer pads with rounded corners

If you’d like to discuss a bespoke packaging solution, or have more questions regarding our envirolite range, get in touch – we’re always happy to help!

22 December 2020

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