Corrugated plastic dividers and internal separators

Cellular polypropylene (alveolar/ currugated plastic, akylux, cartonplast, duraflex, triplex) is a very resistant material from which internal separators of any size and for any type of packaging can be made. These dividers can be produced for large, bulky, sensitive parts, but also for small parts that cannot be packed in bulk.

Although relatively light in weight, corrugated plastic resists impact, breakage and deformation very well, and has thermal and anti-noise properties. It is easy to handle, very easy to clean and maintain, it does not generate dust/ lint, it maintains a pleasant appearance of the packaging, but also the protection of the goods against possible residues.

Corrugated plastic can be extruded to different thicknesses and densities, and has various colors. It can be laminated with technical foam (XPE, XLPE, EVA, EPE, PU) or with textile materials that usually have the role of preventing the scratching of parts (Tyvek, Evolon, Royal Fabric, Softforce fabric, etc.).

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  • Cartonplast internal separators laminated with XLPE foam

    Laminated cellular plastic dividers

    For sensitive goods, it is preferred for the separators to be laminated in order to offer a superior level of anti scratch or anti-shock protection.

    This lamination can be done with various types of materials: foams (PU, XLPE, EPE, PE, XPE, etc.), non-woven material anti-scratch (Tyvek, Evolon, Royal Fabric, Softforce fabric, etc.). This can be done on one or on the both sides of the material, using permanent adhesives or by sewing.

    The non-woven fabric has the role of protecting the components inside the box, and is generally recommended for use on sensitive ones.

    Foam inserts applied to alveolar plastic separators are used to minimize possible damage that may occur during handling associated with manufacturing or transportation operations. The foam can have various shapes, perfectly complementing the surface of the separator. In addition to the fact that the foam helps to protect the packed components, it also has the role of helping manual or automatic handling in a production setting.

    Laminating alveolar plastic separators prevents damage to the parts it comes in contact with, and reduces the amount of scrap that can result from poor packing.

    Laminated separators from cellular polypropylene are mainly used in automotive for the pieces where the aspect is very important.

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  • Alveolar plastic racks

    Corrugated plastic racks

    Corrugated plastic racks are in fact a kind of cabinets with compartments on the vertical or horizontal, depending on the pieces which are placed inside them.

    They can be used like they are, as static storage racks, or with containers, metal platforms or trolleys, flatpac type or injected containers, with injected or twin-sheet lids and pallets, they can be produced on any desired dimensions or design.

    They can be personalized with the codes of the products or projects, logo, during the transport or storage, the access part can be covered for extra protection.

    They are mainly used to store and transport long pieces from production in an ergonomic and efficient way. They are also used for the parts which are still hot after they are out from injection phase, and which need time to cool down until the next process.

    They are light weighted, due to the reduced weight of the corrugated plastic, but in the same time they are very resistant and robust.

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  • Compact plastic divider custom order

    Compact plastic dividers custom made

    This type of separators is produced according to the customizations requested by the clients.

    They are suited for heavy weighted products which can deteriorate a sensitive insert when they are placed in the container.

    Because they have a slightly heavier weight, they protect large or heavy parts much better. They are rigid, durable, stable, and need welding to be fitted. They are ideal for products that contain traces of oil, as they are very easy to keep in good condition by cleaning and washing without affecting the material from which they are made.

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  • Folding corrugated plastic separators

    Folding dividers

    Alveolar plastic folding dividers are the perfect way to optimize return transport by removing them from their packaging and folding for a minimum occupied space. They have the role of delimiting the cells intended for each product and avoiding contact between the parts.

    This option helps as well to reduce the space occupied by packaging, when they are not in use.

    Foldable dividers are used with rigid or foldable wall packaging: injected or alveolar plastic boxes or crates, large containers, containers with modular stacking frames, flatpac containers, metal racks, etc. Their advantage is that, in the case of foldable packaging, the separator does not have to be removed but can be folded simultaneously with the outer packaging, thus saving time that is lost with the separate folding of each.

    Another great advantage is that the crates or pallet boxes they are placed in, can be used also for further projects by simply replacing the separators with new ones adapted to the new pieces.

    Folding and unscrewing the separators are very easy to do, do not require physical effort on the part of the person handling the packaging, increase productivity and job satisfaction.

    In order to be easy to handle, it is important that, when folded, the separator is stable and does not have a strong tendency to return to the loose position, which can be achieved by paying close attention to the design part.

    They are ideal for both small (non-appearance) parts and appearance parts (such as headlights).

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  • Rigid base separators

    Rigid dividers with built-in base

    Rigid cellular polypropylene separators with base are practically smaller boxes made of Akylux type material, which may or may not have, in turn, another series of internal separators that can be customized according to the application.

    The design variants are countless (boxes with different heights, trays, with or without handles, with or without lid, etc.), the products can even be placed in the nest type (nesting) in the case of those with irregular shapes, thus optimizing maximum internal space.

    They are used together with injected or flatpac containers, or other types of medium and large packages.

    They are very easy to handle, can be easily removed from the container in which they are stacked, to be placed on the work belt in the internal logistics flow from one product to another.

    Because they are rigid, they do not need another box on the outside.

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  • There are variants that have parallel cells or variants that have a corrugated structure inside that gives rigidity against bending, in all directions (duraflex, triplex).

    The maximum standard thickness of a plate is 11 mm, but upon request there can be produced multilayer sheets which can reach higher thicknesses.

    Alveolar plastic separators can be placed in any type of packaging: flatpac containers, alveolar plastic boxes, injected plastic packaging (boxes, trays, containers, etc.), metal trolleys.

    Their role is to protect the products against scratches, abrasions, deformation that may occur if the products are improperly packaged, to organize the interior of the boxes/ shuttles/ containers in which these products are placed, to use and take advantage of the entire internal space available by packing as many products as possible, without causing damage during storage and transport. The products can also be placed ‘nested’, which means that they are interspersed so that the inside of the packaging can be used to the fullest. In this way, the transport costs and, implicitly, the production in the case of the delivery of components are made more efficient.

    An example of “nested” packaging is shown in the image below:


    Nested packaging


    Internal separators significantly increase the ergonomics of the operators’ activity, the handling efficiency in production, and automatically increase the working speed and productivity.

    Alveolar plastic has an advantageous price and is very flexible in the construction of the interior design of the boxes, thus streamlining the costs associated with packaging.

    They can be easily printed by various techniques such as: screen printing, hot printing, flexo printing.

    Internal separators also take advantage of the material they are made of:

    • Reduce shipping costs due to light weight
    • Reduce packaging costs because they are returnable, reusable and have a long service life
    • They can be produced from the alveolar plastic version with ESD properties, antistatic treatment or VCI
    • Recycle at the end of its life

    Cellular polypropylene separators do not absorb moisture and are resistant to acids and fats. It resists very well in cases of mechanical shocks, is anti-corrosive and has a high resistance to discoloration.

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