How Is Corrugated Plastic Made?

The production of corrugated plastics begins with polypropylene resin pellets, which serve as the raw material. This material is fed into an extruder (along with color resin) that melts them at a high temperature. Once molten, the plastic is forced through a die that shapes it into the sheet structure that we use in conversion.

The plastic sheet cools as it exits the extruder. It is then cut to the required size and shape, often in huge sheets or boards. These finished products can be further customized through printing, cutting, or laminating processes to meet specific industry requirements. The result is a versatile and durable material suitable for various applications, from signage to protective packaging.

Benefits of Utilizing Corrugated Plastic

Employing corrugated polypropylene in various applications offers the following benefits:

  • Corrosion Resistance

    Unlike metals, this plastic type does not corrode or rust. The agricultural industry — where materials are exposed to varying weather conditions — leverages this feature to construct protective farming structures and signage. Similarly, laboratories and manufacturing facilities use corrugated items to ensure that their tools and equipment remain unaffected by chemicals and corrosive substances.

  • Cost-Effectiveness

    The material offers a cost-effective solution for businesses because of its competitive pricing compared to wood or metal. Its durability also significantly reduces maintenance and replacement expenses, making it an economical choice for those looking to cut costs. In addition, its resistance to wear and tear ensures that investments in products made from this material yield lasting value.

  • Customizability

    Customizability is a key advantage of using corrugated polypropylene, enabling businesses to tailor the material to their specific requirements. Through printing, cutting, and laminating techniques, they can create visually appealing signage and packaging with graphics and branding. This adaptability allows them to effectively communicate their brand, product information, or unique design elements.

  • Ease of Handling and Installation

    The lightweight nature of coroplast is a distinct advantage, making it easy to handle and install in various applications. This feature simplifies the assembly of products like display stands, allowing for quick and hassle-free setup at trade shows or events. Moreover, it facilitates the rapid building of temporary zones — such as partitions and protective barriers — in the construction industry.

  • Enhanced Insulating Properties

    Corrugated plastic’s inherent insulating properties make it an excellent choice for applications requiring thermal and sound insulation. In construction, it can create temporary structures that maintain comfortable interior temperatures, such as on sites or for outdoor events. It can also be used as an effective insulating layer in packaging, protecting sensitive goods from temperature fluctuations during transit.

  • Light-Blocking Characteristics

    The light-blocking qualities of the material are particularly useful in applications where light control is critical. Its intrinsic opacity effectively blocks illumination, making it an ideal option for establishing privacy and security barriers or enclosures. For example, it can be used to create dividers in spaces where maintaining a darkened setting is necessary, such as in theaters or laboratories.

The corrugated plastic manufacturing industry has seen innovations in recent years, driven by sustainability concerns, industrial breakthroughs, and changing consumer preferences. Here are some notable trends and technologies:

The corrugated plastic manufacturing industry has seen innovations in recent years, driven by sustainability concerns, industrial breakthroughs, and changing consumer preferences. Here are some notable trends and technologies:

Automation and Robotics

Integrating automation and robotics into corrugated manufacturing processes boosts productivity and cuts labor expenses. Robots now perform various roles, from precisely stacking finished items to conducting quality control checks. Furthermore, automation streamlines the design and prototyping development process, making it faster and more efficient.

Supply Chain Management

Circular Economy Initiatives

Packaging companies prioritize waste reduction by emphasizing the recyclability of corrugated materials and promoting recycling practices among consumers. Many are also exploring methods to reuse materials, such as offering reusable packaging solutions or repurposing products for secondary uses. These circular economy initiatives align with broader sustainability goals and demonstrate the corrugated plastic manufacturing industry’s commitment to conserving resources.

Design 2 Part

Digital Printing

The advancement of digital printing technology enables cost-effective short-run and customized packaging solutions. This is a significant advantage for small businesses and brands seeking to differentiate themselves. It also eliminates the need for traditional printing plates, making it more economical for smaller print quantities.

Specialized ESD Needs

Smart Packaging

Smart packaging is a growing trend in the corrugated plastic material industry due to the desire for enhanced consumer engagement and supply chain efficiency. RFID tags and QR codes are key components of this technology, allowing for seamless product tracking throughout their supply chain journey. These innovations improve inventory management and logistics and enable consumers to access additional information about their purchased products.


Sustainable Materials

Due to heightened environmental awareness, sustainable materials became a focal point in the packaging industry. Corrugated plastic manufacturers are taking steps toward sustainability by adopting eco-friendly practices. This includes using boards crafted from post-consumer and post-industrial recycled content to reduce the demand for new raw materials and lessen the environmental impact of production.

Partner With Kiva Container for Top-Notch Corrugated Plastic Manufacturing Solutions

Kiva Container has been a leader in designing, fabricating, and delivering reusable packaging for over two decades! Our expertise encompasses various packaging options, including blister packs, clamshells, boxes, trays, handling totes and sleeves. We are also proud to serve specialty industries such as aerospace, medical, pharma, agriculture, and other niche areas.

Contact us for more information! You can also request a quote now.

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