Layer pads
Between rows of product on a pallet, so weight spreads and the layer below is not crushed.
Corrugated packaging · Lahore
Corrugated Sheets
Board supplied flat and cut to your size, in the ply the job needs — for layer pads, separators, protection, or your own conversion.
Where flat board is the right answer
Separators
Between items inside a crate or carton, to stop contact and scuffing in transit.
Protection
Covering floors, surfaces and finished goods during handling, storage or a fit-out.
Your own conversion
Board bought flat, for businesses that cut and make up their own packaging in-house.
What to send us
- The finished sheet size you need
- The ply — or a description of the job, and we will suggest one
- Quantity, and whether it is a repeat requirement
Sheets are usually the cheapest thing we make per square metre, and often the cheapest way to stop transit damage. If you are losing product to crushing or scuffing on the pallet, it is worth asking about before redesigning the box.
Which ply a sheet should be
A sheet is not carrying a load the way a box is — it is spreading one. That changes what you are specifying for. A layer pad between rows of tins has to stop the weight above concentrating on the rims below, and that is about rigidity across the span rather than crush resistance.
As a rough guide: 3-ply for pads between light and medium goods, and for protection sheets during a fit-out. 5-ply where the sheet spans wider, sits under real weight, or has to stay flat when picked up by one edge. 7-ply where the sheet is effectively acting as a base or a deck.
The paper grade matters as much as the ply — see GSM and BF explained. A 5-ply sheet in a poor board grade will sag where a good 3-ply would not.
The words the trade uses
Flat board goes by several names depending on where it sits in the pack, and they are worth distinguishing when you order — they are not interchangeable.
| Term | Where it goes |
|---|---|
| Layer pad | Between rows of product on a pallet, so weight spreads across the layer below. |
| Separator | Between individual items inside a carton, to stop contact and scuffing. |
| Top and bottom sheet | Capping a pallet, protecting the top layer and giving the strapping something to bite. |
| Protection sheet | Covering floors, counters or finished goods during handling or a fit-out. |
| Blank | Board cut and creased ready for you to fold and make up yourself. |
Ordering sheets
Sheets are cut to the size you give us, so tell us the finished dimensions and the ply. If the sheet has to fit inside something — a carton, a crate, a pallet footprint — give us that measurement instead and let us work the sheet back from it, allowing for the fact that board is cut to a tolerance rather than machined to one.
If you want the sheet creased so it folds, say so with the order. A creased blank costs a little more than a plain sheet and saves a great deal of time at the packing bench.
Common questions
What are corrugated sheets used for?
Anything that needs board but not a box: layer pads between rows of product on a pallet, separators inside a crate, protection between stacked goods, floor and surface covering during a fit-out, and as raw material for businesses that cut and convert their own packaging.
What is a layer pad?
A flat sheet placed between layers of product on a pallet so the weight above spreads evenly and the layer below is not crushed or scuffed. It is the cheapest way to stop transit damage on stacked goods.
Can we order sheets in our own sizes?
Yes — sheets are cut to the size you give us. Tell us the finished dimensions and the ply, and how many you need.
Which ply should sheets be?
It follows the job. 3-ply is enough for layer pads and light separation; 5-ply where the sheet carries real weight or has to stay rigid across a wider span. If you describe what it is going between, we will suggest one.
Before you specify
Worth reading first
What is a master carton?The outer box nobody sees — what it does, how to size one around your inner packs, and what has to be printed on it.How many pieces per carton?Carton quantity explained — what PCS/CTN means, how to work out how many fit, the counts this trade packs in, and the weight that caps them.
No price list, and that is deliberate
Tell us what you need to pack
Every job is specified for one customer, so cost depends on size, board, quantity and print. Describe the product and the journey it makes, and we will propose a specification and quote it.
Request a quote