When it comes to packaging, your business has plenty of options, and honeycomb packaging is quickly becoming one of the most popular.. If you’ve heard the term but aren’t quite sure what it is or why it matters, this article is for you.
Keep reading to learn:
Many businesses are making the switch to honeycomb packaging, and once you understand the benefits, you might be ready to do the same.
Honeycomb packaging gets both its name and strength from nature. Inspired by the hexagonal structure of beehives, this type of packaging is made from kraft paper formed into a network of interlocking hexagonal cells.
There are several ways to fabricate honeycomb packaging. Some versions are made by bonding layers of paper into rigid, board-like structures. HexcelPack products are engineered with precision-cut slits in kraft paper. When stretched, the paper expands accordion-style into a flexible honeycomb pattern that provides excellent shock absorption and surface protection.
There are many advantages to using honeycomb packaging, making it a smart choice for businesses of all sizes. One of the most important is that it’s made entirely from paper, not plastic. That’s one of the many reasons it has gained so much traction in recent years, with many companies replacing traditional plastic packaging with this more sustainable alternative.
In fact, the global honeycomb packaging market was valued at over $3 billion globally last year, with North America accounting for a third of that. And growth isn’t slowing down. As demand rises across industries, this eco-friendly solution is expected to expand even further. Here are three key reasons why.
The hexagonal structure of honeycomb packaging is engineered for performance, offering superior strength compared to traditional packaging materials, such as plastic bubble or foam.
Its interlocking paper cells expand to form a flexible yet resilient cushion around items, evenly distributing impact and preventing damage during transit or storage. Unlike plastic materials that compress or degrade over time, honeycomb packaging maintains its form, delivering consistent shock absorption from packing to unboxing.
This built-in strength and flexibility make honeycomb packaging ideal for everything from small, delicate items to large, bulky shipments. It helps reduce breakage, lower return rates, and ensures your products arrive safely, no matter how far they travel.
HexcelPack manufactures a complete line of honeycomb packaging materials, including product wrap, void fill, protective mailers, and pallet wrap. These include:
Because honeycomb packaging expands as it stretches, you can use less material to get the job done. Unlike traditional packaging that often requires multiple layers of filler, honeycomb wrap creates a secure fit with minimal waste. That means you can pack efficiently without overstuffing boxes with excess cushioning.
Using less material doesn’t just reduce waste, it can also result in real cost savings for your business. Lower packaging volume means fewer supplies to order and store, and lighter packages can help reduce shipping costs over time. With less material to handle, the packing process becomes quicker and easier, helping teams move faster and more efficiently.
This is especially true with product wrap like HexcelWrap®. The hexagonal cells allow the wrap to cling to itself, so there’s no need for tape or additional adhesives. Whether wrapping glassware, ceramics, or framed artwork, the material stays securely in place without extra steps.
It’s also incredibly user-friendly. Workers can dispense and apply the wrap manually without any special tools or training. That makes it a great choice for checkout counters, fulfillment stations, or any setting where speed and simplicity are key.
Honeycomb packaging offers significant benefits over plastic and synthetic materials when it comes to both safety and environmental impact. It’s completely plastic-free, meaning it doesn’t expose workers or customers to harsh chemicals or microplastics. Instead, it’s made from kraft paper sourced from renewable materials and produced using environmentally-conscious processes.
In a time when sustainability is more important than ever, honeycomb packaging stands out as a responsible alternative to traditional plastic-based packaging.
Many businesses are switching from plastic packaging to sustainable honeycomb packaging made from paper, and for good reason.
Plastic packaging often ends up in landfills. Even when technically recyclable, plastic typically requires specialized processing facilities that aren’t available in many communities. As a result, it can sit in landfills for decades or even centuries, slowly breaking down and releasing microplastics and other pollutants into the environment.
In contrast, paper honeycomb packaging is curbside recyclable, making it easy for both businesses and consumers to dispose of responsibly. It can also be composted or baled and resold. And if it does end up as litter or in a landfill, it’s 100% biodegradable (unlike plastic).
Even if they are technically recyclable, they require special processing facilities that are not available to every community. As a result, it can sit in landfills for decades or even centuries, gradually breaking down and releasing harmful microplastics and other substances into the environment.
Today’s consumers are more eco-conscious than ever. Surveys show that many not only prefer sustainable packaging, but are also willing to pay more for it. For e-commerce businesses especially, using paper-based packaging like honeycomb wrap can be a powerful differentiator and help build trust with environmentally minded shoppers.
Governments around the world are beginning to mandate more sustainable packaging practices. For example, the European Union is introducing regulations that will require sustainable packaging, with similar legislation expected in other regions. If your business ships internationally, or plans to in the future, transitioning to sustainable packaging now helps you stay ahead of regulatory changes and avoid costly disruptions later.
HexcelPack was the original creator of honeycomb packaging materials and continues to lead the industry with a range of sustainable packaging products and dispensers tailored to your business needs.
Ready to make the switch to honeycomb packaging for your company? Contact our team today. We’ll evaluate your current packing process and recommend solutions to ensure a seamless transition to sustainable packaging.