A layer pad goes between two tiers of product inside a stack, and its job is narrower than a pallet pad: separate the tiers, spread the weight of the upper tier, and let a partial stack be broken without the layers locking together. Height matters here, because every millimetre of pad multiplies by the number of tiers in the container.
Why thin boards win in a tier stack
A layer pad that is too thick wastes container height and, worse, adds a soft layer that compresses under load, so the stack settles and the strapping goes loose. A 10 mm honeycomb pad with a small cell is stiff in the plane that matters and barely compresses at all.
The pad also has to survive being handled. A thin solid board creases at the corner when a layer is slid into place; a honeycomb core board resists that because the core carries load in the same direction the board is being pushed.
Specification at a glance
Layer pads are usually the thinnest board in a consignment, and the choice is between 10 mm and 15 mm with a 4-6 mm cell. Anything heavier is normally a pallet pad rather than a layer pad.
| Product above | Thickness | Core cell | Reason |
|---|
| Cartons | 10 mm | 6 mm | Blocks carton edges, minimal height |
| Flat panels | 10 mm | 4 mm | Dense surface under a line contact |
| Printed packaging | 10 mm, white facing | 6 mm | Clean surface at unpacking |
| Heavy machined parts | 15 mm | 4 mm | Point loads without crushing |
| Soft goods | 10 mm | 8-10 mm | Light separation only |
Matching the pad to the product above it
For cartons, the pad only has to stop the upper carton edges pressing into the lower ones, so 10 mm with a 6 mm cell is enough. For flat products with a hard edge, such as panels or machined parts, the contact is a line rather than a face, and a 4 mm cell at the same thickness gives a denser surface under that line.
For soft or printed products, the pad should be smooth and dry. Kraft facing is standard; a white facing is used where the pad is visible when the customer opens the pack.
Cutting, counting and stacking in the container
Pads are cut to the layer footprint, normally with a 5-10 mm inset so they do not rub on the carton walls. Bundles are counted and strapped so the packing line takes one bundle per tier rather than counting sheets by hand.
Because pads are flat and light, they are usually shipped on the same pallet as the product they protect, or nested in the container void. Tell us the tier count per pallet and we will bundle to that number.
Questions buyers ask before ordering
Is a layer pad the same as a pallet pad?
No. A layer pad separates tiers inside a stack; a pallet pad sits on the deck and carries the whole stack. They are often different thicknesses.
How thin can a layer pad be?
10 mm is the practical minimum on our lines, because the board starts at 10 mm and a thinner sheet would not span the tier gaps.
Will the pad compress and loosen the strapping?
A honeycomb pad compresses far less than foam or a soft board, which is why it is preferred where strap tension must hold over a long route.
Can pads be printed with the tier number?
Yes, on the facing paper, subject to the artwork and the print method. It is a simple way to keep a mixed stack in order.
Do you bundle by tier count?
Yes, tell us how many pads per tier and we will bundle to that figure and label the bundle.
For a quotation, post the product dimensions, load and destination port to mona@hengnicepacking.com.
