A divider panel separates products inside one carton or one stillage, and it has to do that while staying straight. Corrugated dividers bow between the slots once the compartments are loaded; a honeycomb panel holds its plane because the core carries compression in the thickness direction, and it can be die-cut into slots without collapsing at the cut.
Where corrugated dividers give up
A fluted board is stiff along the flutes and soft across them. A tall divider standing across the flutes bows into the neighbouring compartment as soon as one side is loaded. The usual fix is a double wall or a flute direction change, which costs material and still leaves a soft edge.
A honeycomb panel is stiff in both directions in the plane, so a divider stands straight with the same wall thickness all round, and the slot edges stay square after die-cutting.
Specification at a glance
Dividers are normally 10-15 mm thick with a 4-6 mm cell, because slot walls need density rather than thickness. A thicker board with a large cell cuts badly and leaves a soft slot face.
| Use | Thickness | Core cell | Note |
|---|
| Carton compartments | 10 mm | 6 mm | Single panel with slots |
| Crate grid | 15 mm | 4-6 mm | Positive fit into the frame |
| Stillage separators | 15-20 mm | 4 mm | Resists side load |
| Tall divider above 400 mm | 15 mm | 4 mm | Keep the slot pitch even |
| Glass or stone slots | 10-15 mm | 4 mm | Line the slot faces |
Design rules that avoid a failed die-cut
Keep at least one cell width of material between two slots. Cutting too close leaves a wall of loose core that folds on the first load. Slot depth is limited by the same rule: a deep narrow slot in a 10 mm board is fine, the same slot in a 25 mm board is fragile.
Radius the internal corners of a slot. A square internal corner concentrates stress and is the first place a divider cracks. A 3-5 mm radius costs nothing and removes most breakages in transit.
Use inside cartons, crates and stillages
In a carton the divider is usually a single panel with slots, sitting on the layer pad. In a crate or stillage the divider becomes a grid, and the panels need a positive fit into the frame so the grid cannot shift when the crate is tilted.
For glass, stone or machined parts, line the slot faces with a soft material if the part is finished. The divider controls position; it does not cushion by itself.
Questions buyers ask before ordering
Can dividers be die-cut to our layout?
Yes, from your drawing. Slot pitch, depth and corner radius are the three things we check before quoting a die.
What is the minimum wall between slots?
At least one core cell width, and more where the divider is tall. Below that the wall folds under load.
Is honeycomb better than corrugated for dividers?
For tall dividers and repeated handling, usually yes. For a light carton with short compartments, corrugated is cheaper and adequate.
Do you supply the outer carton too?
No. We make the honeycomb board and the die-cut components; the carton is normally sourced by the converter.
How are dividers shipped?
Flat, bundled by component, labelled. Assembled grids are shipped flat and folded at the packing line.
Share the drawing or the four key numbers with mona@hengnicepacking.com and we will confirm feasibility before quoting.
