Corrugated Pads

SupplyLand carries corrugated pads and cardboard layer sheets in a full range of sizes and wall strengths for palletizing, stacking, and in-box product separation. Use corrugated layer pads as divider flats between rows of products inside a corrugated box, or as sacrificial top and bottom sheets to protect contents from crush damage. Our large corrugated pads are built for pallet-scale work: place them between stacked layers on a pallet to distribute weight evenly, reinforce the top of a loaded pallet before wrapping with stretch film, or use them as liner sheets inside bulk cargo containers.

Every corrugated cardboard pad we stock is made from the same fluted board used in shipping boxes, so you get reliable rigidity without unnecessary weight. Single-wall pads handle most general stacking and separation jobs, while double-wall and triple-wall options provide extra load-bearing capacity for heavier pallets. For lighter-duty applications like separating printed materials or protecting surfaces during storage, chipboard pads are a thinner, more economical alternative. All of our corrugated pads ship in bulk at wholesale pricing.

What is the difference between corrugated layer pads and large corrugated pads?

Corrugated layer pads are smaller sheets designed to fit inside corrugated boxes. They work as divider flats between rows of bottles, jars, cans, or other products to prevent contact damage. Large corrugated pads are full-pallet-sized sheets (typically 40 x 48 inches or larger) used between pallet layers to spread weight across the load and prevent lower boxes from crushing. Think of layer pads as "inside the box" protection and large pads as "on the pallet" protection.

What wall thickness should I use for corrugated pads?

Single-wall corrugated pads are the standard for most applications: in-box layer separation, surface protection during storage, and light to moderate pallet stacking. Step up to double-wall pads when pallet loads exceed 1,000 lbs or when you need the pad to serve as a rigid lid or base for a bulk container. Triple-wall pads are the heaviest option and are typically used as structural reinforcement in high-weight industrial palletizing or as reusable layer dividers in warehouse racking systems.

When should I use corrugated pads instead of chipboard pads?

Corrugated pads have a fluted core that gives them significantly more rigidity and load distribution than flat chipboard. Use corrugated pads anytime the pad needs to bear weight (pallet layers, box bottoms under heavy products, sacrificial tops to prevent crush). Chipboard pads are thinner, lighter, and less expensive. They are a good fit for separating lightweight items, backing printed materials, or adding a stiffener inside a mailer. If you are unsure, corrugated is the safer default for anything involving stacking or transit.

How do I use corrugated pads when palletizing a shipment?

Start by placing a large corrugated pad on top of the empty pallet as a base layer to bridge gaps between deck boards. Stack your first tier of boxes, then lay another pad on top before starting the next tier. Repeat for each layer. Finish with a pad on the very top to protect the uppermost boxes from strap marks and fork damage, then secure the load with stretch film or strapping. For extra corner protection on high-value loads, add edge protectors before wrapping. This approach distributes weight across each layer and dramatically reduces crush damage during transit and warehouse stacking.

What sizes do corrugated pads come in?

Corrugated layer pads are available in common box-interior dimensions, starting as small as 5 x 7 inches and scaling up to around 24 x 36 inches for larger cartons. Large corrugated pads cover standard pallet footprints, with 40 x 48 being the most popular size for North American pallets. Oversized options are available for non-standard pallets or bulk containers. If your application falls between standard sizes, corrugated pads can be trimmed on site with a utility knife to fit.