Honeycomb board cushions in a different way from foam. Foam absorbs impact by compressing; honeycomb absorbs it by collapsing cell walls in a controlled way and, until it does, it holds its thickness. That matters inside a carton, because a cushion that has already settled before the truck moves is no longer protecting anything.
The inner liner position
In furniture and appliance packaging the honeycomb board sits inside the outer carton, against the product, as an inner liner. It is the layer that meets the product face, spreads the point where a corner or a handle would otherwise press into the carton, and gives the pack a flat surface for the wrap.
This is the use we build most of this board for, and it explains why the board is specified by area and thickness rather than by a cushion curve. The liner protects a face, not a single fragile point.
Specification at a glance
Cushioning liners are usually 15-30 mm, with the cell size chosen for how much local deformation is acceptable on the product face.
| Product face | Thickness | Core cell | Reason |
|---|
| Flat lacquered panel | 15 mm | 4-6 mm | Stiff, no pressure mark |
| Curved or moulded shell | 20-25 mm | 8-10 mm | Conforms slightly |
| Appliance side panel | 20 mm | 6-8 mm | Large face, moderate drop |
| Furniture top | 25-30 mm | 8 mm | Soft contact over a wide area |
| Protruding handle | 20 mm with recess | 6 mm | Recess, do not compress |
Thickness, cell size and what the product can tolerate
A 20-30 mm board with a 8-10 mm cell gives a softer, more forgiving liner that conforms slightly to a curved face. A 15 mm board with a 4-6 mm cell is stiffer and better against a flat, hard face where the risk is a pressure mark rather than a dent.
Where the product has a protruding feature, such as a handle or a hinge, cut a recess in the liner rather than compressing the board over it. A compressed cell has already used its cushioning travel.
Foam, EPE and honeycomb side by side
Foam and EPE are better at absorbing a single high drop and can be moulded around a shape. Honeycomb is better at holding a flat face, resisting compression over a long route, and staying in the paper waste stream at the destination.
Where a pack needs both, the practical combination is a honeycomb liner for the face and a foam block at the corner that takes the drop. That is more honest than specifying honeycomb for a job it cannot do.
Questions buyers ask before ordering
Can honeycomb replace foam in a carton?
For flat faces and general handling, often yes. For a single high drop onto a corner, foam still does the job better.
What thickness for a refrigerator side?
20 mm with a 6-8 mm cell is a common starting point; the pack design and the drop height should decide it.
Does the board compress over time?
Far less than foam, which is why it is used where the pack must stay tight over a long sea leg.
Is the liner recyclable with the carton?
It is a paper structure, so it goes with the paper waste stream. Check the local mill rules on any coating you add.
Can liners be die-cut to the product outline?
Yes, including recesses for handles, hinges and feet.
Tell us the piece size, quantity per shipment and how it is handled at mona@hengnicepacking.com and we will advise on the board build.
