Recyclable Pallet Blocks for Heavy Loads – Water Resistant Corrugated Dunnage
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Actualizado:
3 mar 2026
< 2 min read
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A Lightweight, High-Strength Alternative to Wood, Steel and Plastic Dunnage
Manufacturers handling heavy goods increasingly seek recyclable pallet blocks that reduce weight, improve ergonomics, and support sustainability targets — without compromising load performance.
Kinnareds Well, part of Ryleon, has developed water-resistant corrugated dunnage (corrugated pads) designed to replace wood, steel, and plastic pallet blocks in demanding industrial environments.
These engineered corrugated pads function as spacer blocks, stacking blocks, and load supports for heavy goods — offering high compression strength while remaining lightweight and fully recyclable.
This article explains how recyclable, water-resistant corrugated pallet blocks can replace traditional wood, steel, and plastic dunnage in heavy-duty industrial applications.
What Are Recyclable Corrugated Pallet Blocks (Corrugated Pads)?
Recyclable pallet blocks (corrugated pads) are fibre-based load supports used to:
Stabilise heavy stacked goods
Distribute weight evenly
Enable forklift handling
Protect products during storage and transport
Our solution consists of engineered corrugated pads bonded with wheat-starch adhesive and PVA glue, using the same water-based adhesive technology to apply the protective coating. The pads are finished with a water-based coating that enhances moisture resistance while maintaining recyclability.
The coating not only improves resistance to humidity but also increases structural strength by approximately 30%, ensuring reliable performance in both indoor and outdoor environments.
Why Replace Wood, Steel and Plastic Pallet Blocks?
Traditional dunnage materials solve one problem — strength — but create others.
Wood Dunnage
Heavy and material-intensive
Difficult to recycle when contaminated
Inconsistent quality
Steel Supports
Often over-specified
High CO₂ footprint
Excess weight increases transport cost
Plastic Pallet Blocks
Fossil-based material
Increasing regulatory scrutiny
Risk of deformation under sustained heavy loads
For many industries, the real requirement is clear:
Reliable strength under load — without unnecessary weight, material complexity, or harmful environmental impact.
High-Strength, Water-Resistant Corrugated Dunnage
The recyclable pallet blocks combine:
✔ High compression strength suitable for heavy stacked goods
✔ Water-resistant performance in humid environments
✔ Lightweight construction improving ergonomics
✔ 100% recyclability in standard paper streams
✔ FSC®-certified* fibre for responsible sourcing (*FSC® C208912)
✔ Custom-engineered dimensions
Despite their low weight, pilot testing confirms the corrugated pads withstand significant compression loads without deformation under demanding industrial conditions.
Lightweight does not mean weaker — it means material efficiency.
Supporting PPWR and CO₂ Reduction Targets
As customers face increasing pressure from regulations such as the EU Packaging and Packaging Waste Regulation (PPWR) and internal Scope 3 reduction targets, recyclable pallet blocks offer measurable advantages:
Reduced fossil-based material use
Improved mono-material recyclability
Lower transport emissions due to reduced weight
Simplified waste handling at end of life
Fibre-based dunnage provides a practical path toward reducing environmental impact while maintaining operational efficiency.
Comparison: Corrugated vs Wood, Steel and Plastic Dunnage
Criteria | Corrugated (Water-Resistant) | Wood | Steel | Plastic |
|---|---|---|---|---|
Weight | Very lightweight | Heavy | Very heavy | Medium |
Load strength | High | High | Very high | Medium |
Moisture resistance | Water-resistant | Moisture-sensitive | Unaffected | Unaffected |
Recyclability | 100% paper recycling | Limited/variable | Recyclable (energy-intensive) | Often limited |
CO₂ footprint | Low | Medium | High | Medium–high |
Customisation | Highly flexible | Limited | Limited | Medium |
For many industrial applications, corrugated pallet blocks provide sufficient strength while significantly improving weight efficiency and recyclability.
Typical Applications
Recyclable corrugated pads are suitable for:
Construction & Building Materials
Plasterboard and gypsum boards
Insulation panels
Doors and prefabricated elements
Metals & Industrial Goods
Metal sheets
Heavy components
Stacked industrial products
Furniture & Interior
Flat-packed furniture
Cabinetry
Worktops
Logistics & Pallet Systems
EU pallet support
Stacking pads
Interlayers
Recyclable load blocks
Real-World Feedback
“The reduced weight makes a real difference for our employees. These corrugated pads are much easier to handle, while still meeting our load requirements.”
– Pilot customer
“We were initially sceptical about whether paper-based dunnage could handle our loads. The compression tests showed performance comparable to our previous wood blocks.”
– Pilot customer
Technical Overview
Material: Fibre-based corrugated board
Adhesive: Wheat-starch based
Coating: Water-based moisture barrier
Recyclability: 100% paper stream
Certification: FSC® (FSC® C208912)
Custom formats: Available
Interested in Learning More About Waterproof Corrugated Dunnage?
For more guidance or to discuss your specific requirements, we warmly invite you to contact us. Our team will be pleased to explore how recyclable corrugated pallet blocks can support your load performance, efficiency, and sustainability objectives.
About Ryleon
Ryleon is a European group providing sustainable packaging and security solutions that protect physical goods throughout transport and handling. The group specialises in fibre-based protective packaging and tamper-evident solutions, helping customers meet performance, regulatory, and sustainability requirements.
Protecting what matters – our customers’ products and the world we live in.
