Sustainable industrial packaging: Innovation for the future
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Lightweight industrial packaging: Aircell panels as a sustainable solution
Less weight, more stability – the Aircell principle
Industrial packaging must be robust and transport products safely. At the same time, there is growing pressure to reduce transportation costs and operate more sustainably. Aircell air chamber panels offer a practical approach here: they are up to 70% lighter than solid panels with the same stability.
How Aircell panels work
Aircell panels consist of three precisely coordinated film webs. The middle sheet has a 3-dimensional honeycomb structure thanks to a patented thermoforming process. This design ensures high stability with minimum material consumption.
Available versions:
- Material thicknesses: 3 to 16 mm
- Basis weight: 1,000 to 5,000 g/m²
- Material: PP, PS, ABS or HDPE
- 100% recyclable
Areas of application for Aircell panels
Returnable load carrier
Foldable container systems made of Aircell panels enable space-saving return transportation. The material thicknesses 5/2000 to 10/4000 are suitable for medium to heavy goods.
Container rings (GLT containers)
Aircell container rings fit on standard pallets and can be individually configured – with loading flaps, different heights and optional handles or H-profiles for fastening.
Possible advantages:
- Reduced transport weight lowers fuel consumption
- Space-saving storage thanks to foldability
- Reusable over several years
Intermediate layers and partitions
Aircell panels from 3 mm thick protect sensitive goods during transportation. The smooth surface prevents scratches and the honeycomb structure absorbs shocks.
Technical properties (verified)
Based on the manufacturer’s specifications:
| Type | Thickness (mm) | Weight (g/m²) | Bending force max. (N) |
|---|---|---|---|
| 3/1000 | 3 ± 0,4 | 1000 ± 50 | ≥ 45 |
| 10/2500 | 10 ± 0,4 | 2500 ± 100 | ≥ 400 |
| 15/5000 | 15 ± 0,5 | 5000 ± 200 | ≤ 900 |
The plates are:
- Weather and moisture resistant
- Corrosion and rot-proof
- Food safe
- Optionally antistatic (ESD version)
Sustainability through material efficiency
Aircell panels use less raw material than solid panels of the same stability. At the end of their useful life, they can be recycled by type – an advantage over composite materials.
Sample calculation for container rings:
- Standard wooden attachment: approx. 15 kg
- Aircell container ring: approx. 4.5 kg
- Weight saving: approx. 70%
For a truck with 30 containers, this means over 300 kg less transport weight.
Customization options
Aircell panels can be individually configured:
- Color design (also multicolored in one panel)
- Printing possible
- Surface coatings (textile, foam, anti-slip)
- Edges open or closed
Up to 3 loading flaps per ring are possible for container rings, which makes loading and unloading easier.
Who are Aircell solutions suitable for?
Aircell panels could be interesting for:
- Automotive industry: Load carriers for components
- Electronics: Antistatic packaging
- Mechanical engineering: Robust transport containers
- Logistics service provider: Lightweight reusable systems
Comparison with other materials
Compared to wood:
- Lighter (approx. 70% weight saving possible)
- Moisture resistant
- No splinters or nails
Compared to solid plastic:
- Significantly lighter with similar stability
- Lower material consumption
- Damping effect due to air chambers
Compared to corrugated board:
- Reusable several times
- Moisture resistant
- Greater stability
Economic efficiency
The investment in Aircell reusable systems can pay for itself through reduced transportation costs. The actual savings depend on:
- Transport volume and frequency
- Current fuel prices
- Number of rotations
A concrete profitability calculation should be carried out individually.
Use the panel configurator
An online configurator is available at aircell-platten.com, with which you can:
- Choose panel size and thickness
- Compare different materials
- You can request samples directly
Conclusion
Aircell sheets offer an alternative to conventional packaging materials when low weight and good stability are required. The complete recyclability and long service life can help to reduce packaging waste.
The best way to find out whether Aircell panels are suitable for your specific application is to take samples and carry out tests.