Solar modules ship as a pallet of framed glass laminates, tilted and strapped, and the pack load runs through the aluminium frames. The honeycomb board in that pack has two jobs: separate module from module so the frames and glass edges never touch, and give the pack a flat face at the top and base so the straps bear on board rather than on a frame corner.
What fails in a module pack
The glass edge sits a few millimetres inside the aluminium frame, and that recess is where a chip starts. If two modules touch, or if a strap crosses the frame without a spreader, the edge takes the load and a chipped module is rejected even when it tests well.
The second failure is pack lean. Modules are thin and the pack is tall, so any settling at the base shows as a lean at the top, and a leaning pack rubs the frames against each other for the whole voyage.
Specification at a glance
Separators between modules are usually 10-15 mm; the base and top pads are thicker because they spread the strap load across the whole pallet.
| Position | Board | Thickness | Note |
|---|
| Between modules | Separator | 10-15 mm | Corners relieved, 4-6 mm cell |
| Base pad | Pad to pallet footprint | 20-25 mm | Carries the stack |
| Top pad under straps | Pad to pallet footprint | 20-25 mm | Spreads strap load |
| Two-high stack | Top pad, heavier | 25-30 mm | Spans the module rows |
| Long sea leg | Coated facing | 15 mm | No water mark on the frame |
Separator, base pad, top pad
The separator only has to keep two frames apart, so 10 mm with a 4-6 mm cell is enough, and it must be cut to the module size with the corners relieved so it cannot press on the frame corner.
The base pad carries the whole stack and the top pad takes the strap compression. Both are normally 20-25 mm, and both should be cut to the pallet footprint rather than to the module, so the pack has a continuous surface to sit on.
Sea freight and the aluminium frame
A damp paper board against an anodised frame can leave a water mark that shows at inspection. Keep the board dry and wrapped until the pack is closed, and discuss a coated facing for a long sea leg.
Where packs are stacked two high in a container, the upper pallet bears on the top pad of the lower pack. That pad has to span the module rows, so it is specified from the pallet footprint and the stack weight, not from the module.
Questions buyers ask before ordering
Will the separator touch the glass?
It is cut to the frame area with relieved corners so it bears on aluminium, not on the laminate.
Is honeycomb suitable for a 30 module pack?
Yes, as separators and pads. The frame and the strapping carry the pack; the board separates and spreads.
Can the base pad replace a plywood pallet top?
For load spreading across the pallet, often yes. Where the pallet itself must be structural, the pallet stays as it is.
Does the board need to be dry?
Yes. A damp board against an anodised frame is a marking risk on a long route.
Can pads be printed with the module model?
Yes, on the facing, which helps at the installation site.
Share the drawing or the four key numbers with mona@hengnicepacking.com and we will confirm feasibility before quoting.
