Honeycomb pallet pads are paper boards laid on the pallet deck and between tiers of a load, so the weight of the stack is spread over the whole pallet footprint instead of pressing on the carton edges underneath. They replace plywood or solid board in the same position, at a fraction of the weight, and they are cut to the pallet size rather than to a stock sheet.
What a pad actually changes on a pallet
A pallet deck is not flat. Boards cup, blocks sit slightly proud, and the bottom layer of cartons only touches at a few points. Those points carry the whole stack, and the cartons above them deform. A rigid pad turns those few contact points into a continuous surface.
The second job is separating tiers. Where two layers of product meet, the pad stops the upper layer pressing into the lower one, and it lets a forklift pick a partial stack without the layers interlocking.
Specification at a glance
The pad has to be stiff enough to bridge the gaps in the deck and light enough not to add freight. Board thickness and core cell do that work, and both are open on our lines.
| Position | Thickness | Core cell | Why |
|---|
| Top pad under strapping | 10-15 mm | 4-6 mm | Spreads band and film pressure |
| Between tiers | 10 mm | 6-10 mm | Separation, low weight |
| Bottom pad on a rough deck | 20-25 mm | 4-6 mm | Spans gaps without following them |
| Plastic pallet, wide gaps | 25-30 mm | 4 mm | Stiff surface over open deck |
| Export one-way pallet | 10-15 mm | 6 mm | Light, cut to footprint |
Choosing thickness against the deck and the load
A pad that flexes into the gaps is doing less than nothing, because it transfers load to the same few points. For a standard pallet with a sound deck, a 10-15 mm board is the usual starting point. Where the deck is rough, repaired, or a plastic pallet with wide gaps, go up to 20-25 mm so the board spans rather than follows.
Core cell matters as much as thickness. A 4-6 mm cell gives more support points per square metre and a stiffer surface, which is what a pad needs. A 10 mm cell is lighter and cheaper but deflects more under a point load, so it suits a pad that is only separating tiers, not carrying the stack.
Cutting to the pallet, and the width limit
Pads are normally cut to the pallet footprint, 1,200 x 800 mm or 1,200 x 1,000 mm, with a small inset so the board does not overhang and get caught by the fork. Our standard production width is generally up to 1,250 mm, which covers both footprints in one piece; longer sizes are cut to length, so a 1,200 mm wide pad at any length is a normal order.
Where a load overhangs the pallet, cut the pad to the load, not the pallet, and accept that the overhanging corner has no support underneath. A pad that sticks out beyond the deck will be crushed by the first fork entry.
Questions buyers ask before ordering
Can a honeycomb pad replace plywood on a pallet?
In many tier-separation and top-pad positions, yes. Where the pad has to carry a concentrated point load across a wide span, plywood is still stiffer and we will say so.
What size do you cut to?
Any size up to the standard production width of about 1,250 mm, with length cut to order. Pads are normally cut to the pallet footprint with a small inset.
Does the pad need to be waterproof?
Standard board is paper and will soften if it stands in water. For a damp route, discuss a coated or film-faced option before ordering.
How many pads per pallet?
Two is typical: one on the deck and one on top under the strapping. Add a pad per tier when the product is stacked in layers.
What is the minimum order?
It depends on size and construction, and is confirmed with the quotation rather than quoted as a single number.
Send the sheet size, thickness, core cell and facing weight to mona@hengnicepacking.com and we will quote the construction that fits the load.
