If you need a material that can be used for packaging purposes or making signs, partitions, and other industrial applications, then you should consider using corrugated plastic sheets. Sometimes referred to as twin wall polypropylene (PP) sheets, they have several benefits but also some drawbacks. Understanding both their advantages and disadvantages will help you choose the right material.
1. What Is Corrugated Plastic Sheet?
Corrugated plastic sheet is a hollow sheet made up of two layers with ribs inside, made from polypropylene material. This material is common because of its durability, chemical resistance, and easy processability. You can customize it according to their needs because they have a variety of choices for thickness, colors, size, and grades.
2. Advantages of Corrugated Plastic
1. Lightweight and Easy to Handle
The fact that corrugated plastic is lightweight is one of its greatest benefits. Being able to use hollow plastic means that you don’t need to use too much of the material to create stiffness.
For your information, a 4mm PP corrugated sheet may have an approximate weight range of 600-850 g/m2, depending on your specific requirements.
All of this makes your product easier to ship, pack, manipulate and install. If you are bringing large volumes of your product to another country, the low weight can become a very significant factor in your calculations.
2. Durable for Many Applications
Corrugated PP sheets offer resistance against daily handling and bending as well as impact resistance. They are more resistant to tearing compared to many papers and do not lose their shape during handling.
For your information, PP corrugated sheets can have a tensile strength of approximately 25–38 MPa, depending on the grade and specification, depending on specification.
If you require reusable packaging boxes, separators, floor protection sheets, or industrial separators, you can use corrugated plastic for uses that require durability.
3. Resistant to Water and Humidity
Polypropylene is naturally moisture-resistant, which means that corrugated plastic can be used in water.
For your information, water absorption of Polypropylene equals 0.01-0.03%, after 24 hours, based on ASTM D570 testing method, but may vary according to different grades and constructions of polypropylene.
If you know that your package or product is likely to come into contact with humidity, rain, condensation, or even water at all, then using PP corrugated sheets can be beneficial over materials like paperboard, which can deteriorate easily when moistened.
4. Chemical Resistance
Another valuable property of polypropylene is its resistance to chemicals. In other words, corrugated sheets manufactured using this type of plastic can be used in different industries.
However, you should not assume that PP is resistant to all chemicals. If your project involves the usage of chemicals like solvents, oils or acids, you have to provide detailed information to your supplier.
5. Easy to Cut and Fabricate
Corrugated plastic sheets can be shaped and formed into various designs. They can be cut, scored, folded, die cut, welded, and printed according to your needs.
Such characteristic makes the material valuable for custom packaging, dividers, totes, cover, barrier, or signs needs.
6. Reusable
Unlike most single-use packaging materials, PP corrugated material can be used repeatedly in appropriate applications. Due to its moisture-resistance properties and durability, it can be reused in transit and storage.
If you operate with returnable packaging, reusable PP corrugated sheets can be used in container manufacture, dividers, layer pads, and protective packaging.
7. Customizable for Your Requirements
You can choose from sheets of various thicknesses, sizes, colors, weights, and finishes as per your requirement.
If you are an importer, then you can use customization to meet the needs of your customers. You can even cooperate with your supplier to create standards in respect of printing, cutting, folding, and other manufacturing processes.
8. Non-Toxic
Made from polypropylene, corrugated plastic is completely non-toxic to humans and animals. Unlike some plastics that contain harmful BPA, it can withstand high and low temperatures without releasing harmful chemicals. You can use corrugated plastic with confidence for your packaging, displays, signage, and other everyday applications.
9. Affordability
PP corrugated sheets are a cost-effective option to use in your packages and protection. They are lightweight, and as such, they could save you on transportation costs. They are also durable and reusable, which could help you cut down on replacement costs. Although the upfront cost is high relative to other products, their lifespan makes them more cost-effective.
3. Disadvantages of Corrugated Plastic
1. It is not totally eco-friendly or sustainable.
Corrugated plastics are made of polypropylene. Polypropylene is a non-biodegradable material, which means it does not naturally break down easily in the environment.
However, it is recyclable; but not all curbside pickup services recycle it because it is hard to recycle, but recycling centers accept and have the capability to recycle polypropylene products. Polypropylene products are also capable of being reused as plastic boxes, plastic bottles, box dividers, etc. Recycling your polypropylene products helps save the environment because your polypropylene products would not end up in the dump sites. The production of corrugated plastics also greatly affects the environment because of high carbon waste.
2. Standard PP Has Limited UV Resistance
When you intend to use corrugated plastic outside for a prolonged period of time, UV rays become an essential factor to consider.
Prolonged sunlight can have a negative impact on standard PP, leading to discoloration and mechanical degradation. You may order UV-stabilized PP, if you are looking for durability outside.
3. Printing and Adhesion May Require Surface Treatment
PP has lower surface energy, which makes it difficult for printing, painting, coating, and bonding.
If your product needs to have graphics or labels applied to it, or is made up of bonded parts, you must talk to your supplier about surface treatment. This depends on what you need; it could be something like corona treatment.
4. Standard PP Is Not Naturally Flame Retardant
It is possible for regular polypropylene to catch on fire if exposed to heat or any ignition point. As such, you should not expect regular corrugated PP to have some fire performance characteristics.
If your application demands fire safety, you should find out the applicable standard for your market and inquire from your supplier about available flame-retardant materials.
4. Where Can Corrugated Plastic Be Used?
Corrugated plastic can be used in many different industries. Some of the uses are:
- Reusable packaging
- Layer pads and separators
- Industrial partitions
- Agricultural packaging
- Automotive packaging
- Protective covers
- Floor & surface protection
- Advertising signs & boards
- Retail display
- Temporary partitions
- Storage and transport products
Because you can tailor the thickness, size, color, and fabrication according to your needs, it is flexible enough to suit many products.
5. Frequently Asked Questions
Q1.Is the higher initial cost of PP corrugated sheets a disadvantage?
Yes, the first cost might be higher in comparison with some other materials like ordinary cardboard. It might be an issue for you if you have a limited budget, but it is worth considering that PP corrugated sheets can last a long time and be used again.
Q2.What makes PP corrugated sheet easy to clean?
Yes. The non-porous nature of plastic makes the material easier to wipe clean compared to porous materials. This may be especially helpful in your reusable packaging and industrial applications.
Q3.Does choosing a thicker PP corrugated sheet always solve its disadvantages?
No. Thicker sheets have higher strength and stiffness, but at the same time they require more material, become heavier and more expensive. It is up to you to select the most appropriate thickness.
Q4. Is the low weight of PP corrugated sheet ever a disadvantage?
Yes, in certain cases. If you have to use a material that is heavy or highly stable on the basis of mass, light weight may be an issue. Its lightweight nature may require additional reinforcement or a different material.
Q5.Can PP corrugated sheets reduce the weight of your packaging?
Yes. The structure of their flutes makes them stiff enough but at the same time light in weight.It means that you can make packaging without extra weight.
6. Conclusion
Corrugated plastics provide a useful combination of strength, light weight, waterproof nature, recyclability, and flexibility. Although corrugated plastic has some disadvantages, picking the right grade, thickness, and surface finish will make it work better for you. At PurePack we offer quality PP corrugated sheets according to your specifications.
