Corrugated plastic dividers and internal separators
Cellular polypropylene (alveolar/corrugated plastic, AkyLux, Cartonplast, Duraflex, and Triplex) is a resistant material suitable for assembling internal separators of various shapes and sizes to fit any container. These dividers can be produced for large, sensitive parts and small parts that cannot be packed in bulk.
Although light in weight, corrugated plastic is resistant to impact and deformation, handles humidity well and adds thermal and anti-noise properties. It is easy to handle, clean and maintain, and does not generate dust or lint. Corrugated plastic maintains a pleasant exterior appearance and crucial interior protection for the goods.
Corrugated plastic may come in various thicknesses, densities and colors. It can be laminated with technical foam (XPE, XLPE, EVA, EPE, PU) or with textile materials that protect the content of the packaging from scratching (Tyvek, Evolon, Royal Fabric, Softforce fabric and others).
Laminated cellular plastic dividers
Sensitive goods are best packed using laminated separators to ensure proper anti-scratch or anti-shock protection.
Lamination can be done using foams (PU, XLPE, EPE, PE, XPE) or non-woven anti-scratch material (Tyvek, Evolon, Royal Fabric, Softforce fabric etc.). One or both sides can be padded using permanent adhesives or by sewing.
Non-woven fabrics are adequate for the most sensitive pieces.
Foam inserts applied to alveolar plastic separators are used to minimize damage caused by shocks during transport or handling. The foam can have various shapes adapted to the packaging needs served by the partition. Foam protection may also serve as help along manual or automated production lines.
Laminating alveolar plastic separators prevents damage to stored or transported parts and reduces the amount of scrap resulting from poor packing.
Laminated separators from cellular polypropylene are mainly used in the automotive industry for pieces that need to maintain a perfect surface.
Corrugated plastic racks
Corrugated plastic racks are partitioned cabinets. They can be used as they are, for storage, or as dividers inside various containers, like metal platforms or trolleys, Flatpac or injected containers, with injected or twin-sheet lids and pallets. They can be produced in any size.
They can be personalized with product codes, logos, and other essential information. During transport or storage, the front access can be covered for extra protection.
They are mainly used to ergonomically and efficiently store and transport long pieces. Sometimes used for parts that come out hot from an injection machine and need cooling before their following process.
They are lightweight but robust due to the corrugated plastic typical alveolar structure.
Custom-made compact plastic dividers
These separators are produced according to the needs of the client’s project.
They are suited for heavy-weight products that could damage the softer inserts or separators.
Compact plastic is slightly heavier than corrugated plastic and more rigid, durable, and stable.
Three-dimensional structures are produced by welding.
This material is ideal for greasy products, as they are easy to clean or wash without getting damaged.
Alveolar plastic folding dividers are the perfect way to optimize return transport and storage space by removing them from their host packaging and folding. They separate the parts by defining single cells inside a larger container.
Foldable dividers are used with rigid or foldable containers: injected or alveolar plastic boxes or crates, large containers, containers made of modular stacking frames, Flatpac containers or metal racks. When used in foldable containers, the separator can be folded together with the box, thus saving considerable effort and time.
Combining containers with removable, foldable dividers allows easy repurposing of the containers using new partitions.
Folding and unscrewing the separators is easy for operators, increasing productivity and work satisfaction.
Foldable dividers are carefully designed to remain flat when folded. This vital trait can make the difference between a proper logistic solution and half-measure items that produce more trouble than assistance.
They are ideal for both small parts (hidden in the final product) and apparent parts, e.g., headlights.
Rigid dividers with a built-in base
Rigid cellular polypropylene separators with a base are small boxes made of AkyLux material or similar, which may also contain internal separators, customizable for precise applications.
A wide range of designs is available – boxes with different heights, trays, with or without handles, with or without a lid etc. Products with irregular shapes can be nested inside the box, thus optimizing internal space.
They may be used with injected or Flatpac containers and other types of medium and large packaging systems.
Easily handled or removed from their container and transported between different workstations inside the logistic flow.
Because they are rigid, they do not need a box to contain them and maintain their shape.
Some versions have parallel rows of cells; others are specially designed to deliver structural rigidity against bending in both directions, usually with Duraflex or Triplex.
The maximum standard thickness of sheets is 11 mm, but multi-layered sheets can be produced on demand for higher thickness and improved rigidity.
Alveolar plastic separators can be placed inside any type of packaging: Flatpac containers, alveolar plastic boxes, injected plastic packaging (boxes, trays, containers and others), or metal trolleys.
Their role is to protect contents against scratches, abrasion, and deformation and to efficiently organize the interior space of the boxes/ shuttles/ containers. Optimizing space is optimizing costs in both transport and storage, as long as it’s done safely and properly. The products can also be nested to use the interior space of the packaging to its fullest. Streamlining processes, weight, and space has an important impact in large industries where every cent is multiplied thousands or hundreds of thousands of times.
An example of nested items is shown in the image below:
Internal separators significantly increase the ergonomics of the operators’ activity, the handling efficiency in production, and the operating speed and productivity.
Alveolar plastic is inexpensive and versatile, thus streamlining the costs associated with packaging.
It can be printed in one or more colors, using various techniques: screen printing, hot printing, and flexo-printing.
Internal separators put the virtues of the material to good use by:
- Reducing shipping costs due to their lightweight
- Reducing global packaging costs through their long service life
- Allowing ESD antistatic or VCI anti-corrosive properties
- Being recyclable at the end of their life
Cellular polypropylene separators do not absorb moisture and are resistant to acids and oils. Proper against mechanical shocks, anti-corrosive and highly resistant to bleaching.