What Are Corrugated Sheets and Layer Pads?
Corrugated sheets and layer pads are flat protective materials made from corrugated cardboard or plastic. They are placed between product layers on pallets to:
- Prevent shifting and damage during transit
- Distribute weight evenly across stacked items
- Protect products from dust, dirt, and moisture
- Provide a stable surface for stacking additional layers
How to Choose the Right Corrugated Sheets
Material Thickness (Flute Type)
Single Wall: Lightweight protection for smaller products or inner box layers. Most economical option.
Double Wall: Heavy-duty protection for palletized shipments and heavier products. Offers excellent crush resistance.
Triple Wall: Maximum strength for industrial applications and export shipments.
Standard Sizes
Our corrugated sheets are available in sizes to match common pallet dimensions (48" x 40", 48" x 48") and standard box sizes. Custom sizes available for high-volume orders.
Common Applications
- Warehouse & Distribution: Layer separation on pallets to prevent product damage
- Manufacturing: Protect work surfaces and floors from heavy items
- Food & Beverage: FDA-compliant sheets for food-safe packaging
- Retail & E-commerce: Insert sheets inside boxes for added protection
- Moving & Storage: Protect furniture and fragile items during transport
Why Choose Prism Pak for Corrugated Sheets?
- Wholesale Pricing: Save on bulk orders - no account minimums
- Fast Shipping: Most orders ship same-day or next-day
- Quality Materials: American-made corrugated board for consistent strength
- Expert Support: Our team helps you select the right thickness and size for your needs
Related Products
Maximize your pallet protection with our full line of shipping supplies:
Frequently Asked Questions
What is the difference between corrugated sheets and corrugated pads?The terms are used interchangeably — both are flat corrugated cardboard pieces used for layer protection. In practice, "pads" usually refers to pre-cut standard sizes, while "sheets" may include larger or custom-cut pieces. What size corrugated sheet fits a standard pallet?A 48" x 40" sheet fits a standard GMA pallet, and 48" x 48" fits a square pallet. Prism Pak stocks both sizes along with common box-sized pads, and can die-cut custom sizes on orders of 500 sheets or more. Should I use single wall, double wall, or triple wall corrugated sheets?Use single wall for light product and inner-box layers, double wall for palletized loads and heavier product where crush resistance matters, and triple wall for industrial and export shipments carrying the most weight. The heavier the load stacked on top, the thicker the board should be. How many corrugated sheets do I need per pallet?Plan on one sheet between each product layer, plus one on top for dust protection. A five-layer pallet typically uses four to five sheets. Are corrugated layer pads food safe?Corrugated sheets that touch food directly must be an FDA-compliant food-grade board, and Prism Pak stocks food-grade options for food and beverage operations. Standard shipping-grade corrugated is intended for secondary use — separating layers of already-cased, bagged, or wrapped product — not direct contact with unwrapped food. Can I use corrugated sheets for outdoor storage?Standard corrugated cardboard is not waterproof and will soften and lose strength when it gets wet. For outdoor yards, cold rooms, or other high-moisture environments, use plastic corrugated sheets or wax-coated board instead. |
