Honeycomb Cardboard Sheet 600x400x40

"Honeycomb" Cardboard Sheet 600 × 400 × 40 mm - Extreme Thickness, Extreme Protection

"Honeycomb" paper structure - a forty-millimeter core of hexagonal cells + durable testliner faces - creates an extremely rigid, yet surprisingly light plate resistant to crushing, point impacts, and vibrations. Despite its impressive height, the sheet is over eleven times lighter than a 40 mm wooden plate, and after use, it goes directly into the waste paper stream. The format 600 × 400 × 40 mm will work as a spacer, a distance insert, and a cushioning "nest" in the transport of heavy-duty loads.

🍯 What exactly is a "honeycomb" structured sheet?

Honeycomb sheet is created in three steps:

1. Core expansion – strips of kraft paper are glued with starch glue into a block, then "stretched" to create a rigid network of hexagons with a height of 40 mm.
2. Laminating the covers – both sides are reinforced with testliner (recycled paper), which carries tensile and compressive stresses like the straps of a double-T beam.
3. Cutting to size – the finished plate is laser or tape cut to a size of 600 × 400 mm; tolerance ± 1 mm.

• 🔬 Base material: 100% kraft paper + water-based starch glue.
• 🪶 Surface weight (40 mm): approx. 1.80 kg/m² – still lighter than PE foam 30 kg/m³.
• 📊 Core parameters: height 40 mm · mesh 15 mm · wall 0.2 mm.
• 🌍 Ecology: 100% biodegradable, compostable and recyclable in the waste paper stream.

🧪 Key properties – stiffness + damping

Combines the load-bearing capacity of a wooden beam with the flexibility of foam, protecting the load both during warehouse compression and during violent shocks in transport.

• 🏋️‍♂️ Reliable protection when stacking – withstands pressure up to 2,000 kg / m², so pallets won't flatten even on the lowest layer.
• 📏 Less distortion – stiffness 95% higher than in PE foam minimizes claims caused by crushing.
• 💥 Absorbs shocks – 40 mm core absorbs the energy of a fall from 1.5 m, protecting glass, marble and precision electronics.
• 🔄 Multiple use – recovers ≈85% of height in 30 s, suitable for several transport cycles.
• 🪶 Significant weight reduction – 1.80 kg/m² vs. pine board 40 mm ≈ 20 kg/m²; cheaper freight and lower CO₂ footprint.

One sheet replaces thick wooden plates + PE foam, simplifying packaging and reducing logistics costs.

• 🌡️ From frost to heat – stable parameters from -20 °C to +70 °C.
• 🌧️ Not afraid of moisture – short-term dampness does not reduce stiffness; the product is not intended for constant exposure to water.
• ⚡ Electronics-friendly – antistatic version discharges charges, protecting sensitive components.
• 🍏 Food contact (indirect) – paper and starch glue do not transfer flavors or odors; no certificate for direct contact.
• 🔥 Easy disposal – combustion < 1% ash, high energy recovery.

📦 Typical applications – how you can benefit

• 📑 Heavy-duty pads – stabilize layers of castings, engines and traction batteries.
• 🔄 3D Spacers - you crease wedges and frames blocking loads of 500 kg+.
• 🫧 Protection of XXL stone & glass – marble, granite, 10 mm panes on long routes.
• 🛡️ 40 mm angles – protect stone countertops and premium furniture.
• 📦 Eco-insert for heavy e-commerce – aquariums, hi-fi amplifiers, microscopes.
• 🏗️ XL POS structures – 3 m walls assembled without tools, 30% cheaper freight.
• 🪑 Ultralight furniture – door filling 50 mm, mass reduction by 40%.

🏭 Industries already using 40 mm thickness

• 💻 Electronics & optics – 85″ screen separators, server chassis.
• 🚗 Automotive & aerospace – engine spacers, battery packs, composite panels.
• 🪨 Stonemasonry & premium countertops – granite and quartz sinter transport.
• 🍾 Food & premium beverages – nests for 12 l barrels and 10 kg jars.
• 🥼 Medical equipment – tomographs, tabletop autoclaves.
• 🎨 Large-format POS systems – reusable stage modules.

⚖️ Comparison with PE foam

If you are looking for PE foam sheets, check out our full offer ➜

⚙️ Technical specification

• Material: paper (testliner + kraft)
• Format: 600 mm × 400 mm × 40 mm
• EAN: 5905489972259

♻️ Recycling and reuse – we close the loop

Honeycomb sheet is 100% homogenous paper, so "cleaning up" after it is as simple as throwing out a newspaper.

• 🗑️ Recycling without guessing – you throw it into the blue container along with cardboard and newspapers.
• ♻️ Full cycle closure – the paper mill processes it into new cardboard within a few days.
• 🔄 Second life in the warehouse – after regaining thickness, it serves as a separator for the next cycles.
• 🌱 Composting option – In a BIO facility, it breaks down into humus within a few weeks.
• 🔥 Energy without toxins – burning generates < 1% ash, high heat recovery.

📦 Custom size cartons and packaging personalization

Combine a cardboard cut to the millimeter with a 40 mm sheet to build an all-paper packaging: no plastic, one recycling fraction, maximum protection.

• 🔒 Zero clearance – the format + box eliminates empty spaces.
• 🌍 Zero plastic – the customer throws everything into the wastepaper.
• 💡 A brand that makes an impression – inside/outside printing, eco-look.
• 📦 Less volume = lower costs – compact packages, cheaper freight.
• ♻️ One waste fraction – simpler segregation at the recipient's.

Take advantage of Custom size cartons or add a logo thanks to Printed cartons .

📞 Bulk orders and advice

Contact us - we will set the eyelet 8-25 mm, grammage lic 150-350 g/m², hydrophobic coating or ESD and prepare an offer for your volume.