Corrugated plastic is now one of the most high-demand items in different industries all over the world. Its numerous uses of corrugated plastic sheets in various systems and workplaces contribute to its popularity. Its versatility is evident in its multiple applications, including factory sheds, signage, road signs, and alternative roofing solutions.
The different qualities of corrugated plastics also render them ideal for these industrial uses, especially their strength and flexibility. And they have plastic surfacing that is sturdy enough to endure extreme weather, making them also perfect for outdoor usage. Ultimately, these qualities are what set them apart from other materials that have the same purposes.
But what are corrugated plastics, and how are they made?
What Is Corrugated Plastic
Corrugated plastic is a twin-wall plastic sheet that comprises three polypropylene plastic membrane sections. The two exterior layers, which have the same layout and parallel locations, keep an inner sheet of hexagonal plastic together. The upper surface is smooth, while the other layer is ribbed in a dense waveform to create a sturdy product.
Thanks to this process, corrugated plastics are one of the most compact, durable, and shock-resistant products on the market. Polypropylene is a robust thermoplastic- a material moldable under higher temperatures without much damage- that has a neutral pH. This characteristic lets it tolerate various extreme temperatures, weather, and usage situations for long durations while sustaining minimal damage.
How Are Corrugated Plastics Made
Polyethylene and polypropylene, which are flexible thermoplastics, are the primary materials in manufacturing rigid corrugated plastic. Polycarbonate is also a viable option for corrugated plastic, but it is a much less flexible material, especially in impact resistance and fragility.
The standard manufacturing procedure involves extrusion, meaning it forms materials by forcing them out through a pattern or die. This process pushes molten plastic- the material in this instance- through a die to create the structure’s profile. The die is usually one to three meters wide and produces a plastic sheet up to 25 millimeters thick.
Different Types of Corrugated Plastic
Corrugated plastics can come in three different types- profile sheet, laminated sheet, and honeycomb sheet. Each of these kinds possesses unique advantages that may benefit specific commercial and industrial applications.
Corrugated Profile Sheets
The profile sheet includes an extrusion procedure pushing hot resin via a reinforced steel mold. When you force the wax into the mold, it makes a layer that has flat surfaces on all sides with an I-beam pattern between them. Since it is a continual operation, it can generate lengthy sizes of an item, depending on the need.
The profile sheet is the most flexible type to work on since it comes in various widths and specific sizes.
Corrugated Laminated Plastic
Laminated plastic consists of multiple plastic layers attached along with plastic resin under high temperatures and extreme pressure. Manufacturers produce laminated sheets like corrugated paper, frequently with two layers from each side and a third in the middle. Similar components that require consistent hardness in all directions may also benefit from the molded-macerated process.
Corrugated Honeycomb Sheet
Honeycomb sheets– also known as bubble sheets– typically have two flat surfaces, two adhesive layers, and a honeycomb core. It’s available in various widths, has increased firmness on both sides, and is exceptionally smooth on the surfaces.
Its strength is comparable to I-beams, with the vertical portion as the center and the cover as the flange. The two layers function together to provide more excellent stability to the structure, and the thicker the core, the better. Honeycomb sheets are more costly than the other alternatives, but they have some advantageous features in specific uses.
Brilliant Advantages of Corrugated Plastic
Corrugated plastics are some of the most flexible and valuable materials available today in a variety of industries. They offer an excellent combination of toughness, flexibility, affordability, and lightweight. The following are some of the advantages of plastic corrugated sheets:
Corrugated Plastic Is Versatile
Industrial, commercial, and residential uses are all possible with corrugated plastic sheets. They are most commonly very suitable for different yard and business signages, plastic bags and containers, and recyclable packaging materials. Corrugated plastics are also available in various sizes and shapes, which means custom measurements for specific usages are attainable.
Corrugated plastics have also been the preferred alternative material for portable animal enclosures in recent times. They are so adaptable that there are several little-known yet practical individual usages, just like art projects and creative pursuits. Since corrugated plastics are water-resistant and maintain their strength and stability, they are useful for producing numerous beneficial products.
Corrugated Plastic Is Sturdy and Durable
Corrugated plastics are highly durable since their engineering can tolerate various environmental challenges like extreme weather. This quality renders them suitable for numerous industrial, manufacturing, and commercial purposes, especially outdoor usage. While it isn’t supposed to last indefinitely, it will last a significant amount of time before needing replacement.
Corrugated plastic sheets can keep their structure with time, which is exceptionally suitable for signboards, storage boxes, and containers. They can withstand plenty of abuse before displaying signs of wearing and are resistant to damage from insects and pests. When held indoors and not subject to much deterioration from outside elements, they can even last nearly indefinitely.
Corrugated Plastic Is Lightweight
Corrugated plastic is remarkably lightweight, making it convenient to ship, store, raise, install, and put in place. You certainly would not have any worries about the sheets breaking down or anyone getting hurt should it slip. Its light density also allows you to cut it into any shape or size with ease.
Corrugated Plastics Are Affordable and Cost-Effective
Corrugated plastics are among the most cost-effective products on the market, both cheap to manufacture and buy. Cutting and printing onto them is a low-cost and straightforward process that does not necessitate the use of specific equipment. They also save money due to their reusability: corrugated plastic boxes are reusable about fifty to five hundred times.
Damaged corrugated plastics are inexpensive to replace, and you can purchase as many as your resources can afford.
Corrugated Plastic Is Recyclable
While corrugated plastic has polypropylene- a non-biodegradable material- as the primary ingredient, it is not entirely unsustainable. Recycling facilities can melt and recycle the material into new plastic sheets after yours reached its lifespan. They can then upcycle or remanufacture these sheets into other popular household items like plastic bottles or containers.
However, recycling your plastic consumer products is necessary to prohibit them from ending up as waste in landfills. Manufacturers may also repurchase them or provide recycling services for items that have reached the end of their expected life.
Corrugated Plastics Are Available in Vibrant Colors
Corrugated plastic sheets are available in multiple shades, which should provide many benefits, mostly for signboards and other advertising purposes. You may pick anything a little more vibrant and colorful than the usual bland colors. Furthermore, when exposed to the elements, their shades can last longer than most other materials.
Popular and Practical Uses of Corrugated Plastic
Corrugated plastics have numerous beneficial qualities that enable them for use in a variety of industries. Although most people would associate the material with advertisement signages, plenty more businesses benefit from it. Here are some of the brilliant ways in which commercial and industrial establishments utilize corrugated plastics:
Multiple Kinds of Signages
As mentioned earlier, the most prevalent use for corrugated plastics is various temporary outdoor lawn signs and advertisements. Election campaign signs, real estate signboards, and advertising displays for companies and products are frequent examples of these signages. Furthermore, you can also use corrugated plastics for interior signages in commercial or residential areas.
Corrugated plastic signs are perfect for outdoor application due to the coating and durability to tolerate all kinds of weather. They take a long time to become damaged and exhibit signs of excessive wear, and they are inexpensive to replace. They also come in many different colors, are simple to print on, and are effortless to display in various ways.
Packaging and Storage Boxes
The use of corrugated plastics for boxes and containers is quite widespread in business offices and the packaging industry. Its outstanding combination of lightness and strength makes handling, transport, and storage simple and effective. Corrugated plastic sheets produce excellent boxes for various products due to their design flexibility, reliability, water-resistance, and sustainability.
You can have sheets trimmed to measure so they’re ready to assemble or customize them to the exact necessary form. It has a flexible layout that can be sliced, shaped, or formed with standard tools without breaking, ripping, or shattering. Corrugated plastic boxes are ideal shipping materials since they are cheaper than shipping crates but more durable than cardboard boxes.
Roofing and Architectural Structures
You can employ corrugated plastics to create temporary fences, walls, and a few other protective sheathings. They’re 200 times tougher than glass and five folds lighter than plywood, so they’re ideal for small buildings and makeshift shelters. It’s also perfect for facilities like greenhouses, where the center layer acts as an excellent insulation element.
Transparent plastic sheets are also suitable for greenhouse and garden room roofing because they transmit light throughout the day. They are easy to install and can endure intense temperatures and other environmental elements. Unlike other wood and metal products that need painting to look appealing, they already have natural colors that don’t recede.
Humanitarian Relief Efforts
Plastic sheets are suitable for building temporary structures for humanitarian efforts because of their waterproofing and insulating capabilities. The material is also perfect for making emergency shelters in the aftermath of disasters such as floods, earthquakes, and other natural catastrophes. The lightweight corrugated sheets are convenient to transport by land or air, handle, and install in various frameworks.
Product Displays and Templates
Corrugated plastic is strong enough to make customized product displays for retail shops, trade fairs, and product launches. You can use a wide range of colors and dimensions in your display’s design features to match your merchandise. It may include custom printed signs and a small shelf to showcase various items in your collection.
You can also use corrugated material to create models of homes, aircraft, and other objects for educational or recreational purposes. It’s simple to measure, and you can effectively cut it to fit the size of the installation you’ll be making. Cleaning your model to ensure that it remains clean and attractive for years of display or use is effortless.
Small Pet Shelters
You can make a reliable pet home out of corrugated plastics because they are ﬂexible and sturdy. Enclosures for cats, rabbits, and other smaller pets frequently utilize them since you can attach fixtures like latches and hinges. And they are watertight, washable, and generally easy to maintain- an essential factor for animal shelters.
Pharmaceutical Packaging and Medical Purposes
Pharmaceutical packaging made of corrugated plastic is more robust, flexible, and long-lasting than other products on the market. Another benefit corrugated packaging provides pharmaceutical companies is that it can safely contain any liquid spills. It provides a hygienic, more sterile means of transporting products which is crucial in the pharmaceutical industry.
Corrugated plastics are also handy in an emergency, like when you require a stretcher to transport a person in need. You can also wrap a portion of a sheet around a fracture and tape it into place as a splint. It helps protect the injured body part from impact and retain body heat.
Corrugated Plastic Will Continue to Be Valuable in the Future
Corrugated plastic sheets are functional and brilliant materials for numerous residential, industrial, and commercial applications. With newer applications almost every day, it is also now one of the most valuable products for everyday use. And with such functionality, corrugated plastics are the leading resources for industries, and they’ll remain so in the coming years.
Corrugated plastics are a multi-purpose solution that can withstand moisture, UV exposure, liquids, and even chemical products. Many would consider them the best choice over wood and cardboard options due to their greater flexibility and durability. Corrugated sheets are perfect when you’re searching for materials that are colorful yet nearly transparent, pliable yet firm.
Call Plastic Packaging Solutions for Your Corrugated Plastic Needs
And if you have home projects or business ideas that will need corrugated plastics, Plastic Packaging Solutions can help you. Plastic Packaging has a wide range of high-quality products such as corrugated boxes, polyethylene sheets, laminated rolls, and more. Contact us today to know more or to purchase our corrugated plastic products.