Hexpand suspension packaging cradles a product and holds it in place at the center of a shipping box using a carefully engineered corrugated structure. Instead of relying on void fill items like foam, air pillows, or loose fill, a Hexpand insert expands into a honeycomb mesh that envelopes a product on each side. This absorbs the shock and vibration that packages experience during transit. The product inside is completely safeguarded, remaining in position throughout the entire supply chain journey.
Give Paige Packaging a call today to learn more about our suspension packaging or additional products and services.
How Does the Hexpand Suspension Mechanism Work?
Hexpand starts out as a flat, die-cut sheet of corrugated fiberboard. The sheet expands into a configuration of hexagonal cells that stretch open like an accordion, which gives the material its suspension capability.
Under impact, the cells compress and return to their original shape. This distributes force across the entire structure instead of concentrating it at a single point. Because packaged products are wrapped by the suspension layer, they’re completely supported and remain in place at the center of the box throughout transit.
Retention & Cushioning: Hexpand Solves Two Packaging Concerns at Once
A single Hexpand insert keeps a product in a fixed position while simultaneously absorbing shock, eliminating the separate cushioning step that foam-in-place systems often need. Procurement teams assessing their packaging strategy find that consolidating retention and suspension into one component greatly reduces material costs.
Assembly time also decreases as operators are no longer required to place a product and then pack cushioning material around it. Furthermore, flat-packed Hexpand inserts take up far less warehouse space than other void fill materials, which minimizes inbound freight volume as well.
The Sustainability of Suspension Packaging
Foam inserts and plastic air pillows create a secondary waste stream that many recycling facilities don’t have the ability to process alongside corrugated board. Hexpand contributes to brands’ sustainability efforts since it is made entirely out of paperboard. That means the suspension insert and the outer box can travel through the same recycling stream. Explore Paige Packaging’s commitment to sustainability here.
Reliable Protection for Fragile, Valuable, and Irregularly Shaped Items
Hexpand suspension packaging offers dependable performance for a variety of different products across industries. For example, companies that produce beverages in glass bottles use Hexpand packaging to prevent breakage claims. Electronics manufacturers follow the same principle. They’re able to better protect sensitive items like circuit boards through die cut inserts matched to their product dimensions.
Customization Benefits of Suspension Packaging
At Paige Packaging, we offer custom manufacturing for boxes as well as our Hexpand inserts, designing around the dimensions and weight of each product. While flute profile and board grade are prime influences on load capacity, the cell density of Hexpand packaging takes it a step further, fine-tuning the compression limit of the suspension layer.
Lighter items can usually ship with a single-wall board, but heavier or more dense items often require double-wall construction to preserve suspension integrity under greater compressive force.
Custom die lines and multi-unit configurations are also available to accommodate bottlenecks, angled surfaces, and packages shipping several items at once. Plus, with our extensive printing capabilities, our team at Paige Packaging can create branded or colored inserts for your application.
Discuss Suspension Packaging with Our Paige Packaging Team Today
Hexpand corrugated suspension packaging gives operations teams a more consistent way to protect products, support sustainability goals, and control dimensional weight. At Paige Packaging, we can engineer corrugated boxes, and suspension inserts around your product’s specifications and fragility profile. Speak with a team member today to get started.
Frequently Asked Questions
What is the difference between retention packaging and suspension packaging?
Retention packaging holds an item in a fixed position inside a box. Suspension packaging holds an item clear of the box walls entirely, so shock absorbed anywhere on the exterior doesn’t reach the product.
What products work best with suspension packaging?
Fragile, high-value, and uniquely shaped products benefit the most from suspension. This includes glass bottles as well as electronics and delicate industrial components.
Does assembling Hexpand suspension packaging require special equipment?
No specialized machinery is required for most suspension packaging configurations. The inserts arrive flat and expand by hand into the honeycomb structure, then fold around the packaged item for a snug fit.