Duraflex packaging

Product information

Duraflex is a solid material produced from 3 layers of polypropylene film. The thermoformed core features repeating cell patterns sandwiched between two solid layers. All layers merge and seal during in-line extrusion without glue or extra bonding agents.

The sandwich-type structure gives the material equal resistance over the entire surface. It provides outstanding protection and shock absorption features. The inner cells’ size can vary depending on the thickness of the material, which is available between 3-30 mm. Rigid polypropylene air cell boards balance high strength with low weight. They’re ideal for diverse handling and transport packaging designs.

Duraflex has a material density of up to 6000 g/m2. This makes it suitable for high stability and durability needs in product shipment. It’s great for handling small equipment, as well. Duraflex can undergo optional treatments with various additives. These treatments can confer flame resistance, electrical conductivity, and UV-ray resistance. Further, it has excellent thermal resistance and is unaffected by moisture and most chemicals.

Comparison to other materials used in packaging

Duraflex material offers an extended life to the designed packaging. This makes it a great alternative to one-way solutions. Due to its empty cell core, Duraflex is cost-effective. It uses less material compared to solid plastic sheets, lowering construction costs. In addition, it is lighter than solid panels of equivalent thickness. This allows for easier handling and substantial weight reduction in the overall packaging unit.

For packaging, corrugated plastic sheets only require bending perpendicular to the channel direction. The final packaging might be less stable or lasting if bent along the channel direction. Duraflex offers maximum resistance to the final packaging, no matter in which direction it is bent.

Our 3-layer polypropylene panels surpass corrugated carton boards in strength and stability. This difference becomes noticeable when stacking products. Duraflex packaging can withstand heavy loads without compromising the safety of the packed goods or users. In specific applications, it’s the preferred choice. Especially when safeguarding products from moisture or harmful substances is crucial. Its surface allows for attaching various identification or warning labels. These labels can be removed or replaced as needed.

Compared to wooden versions, Duraflex packaging imposes no shipping restrictions or special maintenance. At the same time, it weighs less than the crates and containers produced from wood. Duraflex contrasts with metal packaging in several ways. It’s lightweight and operates silently in any application. In addition, it offers corrosion and rust resistance.

Converting possibilities

Industrial packaging trends are evolving due to advancing technologies. These innovations enable companies to enhance their fabrication and conversion processes. Our strong market awareness helps us pinpoint materials and equipment that align with our customers’ needs and limitations.

Our knowledge and experience in packaging manufacturing and plastic processing are crucial. They help us evaluate each specific application effectively. This leads to finding the optimal solution for clients.

Duraflex is a top-quality material choice for designing reusable, custom-made packaging. In some applications, it can be useful as unconverted or slightly-converted sheets. Most often, we transform it into finished packaging.

These air bubble polypropylene boards can be precisely and quickly processed by cutting, bending, welding and milling. Their smooth surfaces enable us to print them with your logo or a lot more of other information. Multiple in-line laminating options are available. They involve technical films and offer anti-slip or foam-padded finishes. These finishes are suitable for services that handle parts with sensitive surfaces. They are ideal for parts with delicate surfaces.

The standard color options include gray, blue, and black. These can expand with custom colors to match various preferences for visual appeal and brand promotion.

Lightweight and sturdy, Duraflex is ideal for reusable packaging. It maintains its technical and aesthetic qualities for several years of use. Our durable packaging solutions cater to specific products and applications. They encompass various sleeves for collapsible pallet containers, boxes, intermediate layers, and dividers. These items offer complete customization. This includes material thickness density and packaging design, allowing for various dimensions.

The sleeves are engineered with plastic pallet and lid packaging systems, such as Collibox. They are designed to streamline the handling and transport processes for a wide range of goods. We offer pallet sleeves tailored to our clients’ needs. Depending on their requirements, these can be a single foldable piece or come in multiple parts. The one-piece sleeves can be produced with different configurations, such as M and Z folding.

In contrast, sleeves crafted from multiple parts offer versatility. They come in configurations like C or U shapes, and operators can access either their short or long sides. All sleeves allow customers to achieve volume savings at return transport. This sleeve-packaging system offers flexibility with open or closed edges at the bottom and top. Clients can choose optional return collars and closing and locking systems. These options provide a wide range of custom choices to meet specific needs.

Duraflex crates and trays are sturdy. They offer lasting storage and transport. It is ideal for bulky or lengthy items like pipes and profiles. We offer customization based on product needs. This includes handles, screws, stacking frames, corners, Velcro fixing systems, and label holders.

Intermediate layers and inserts segment large containers and pallet boxes. This arrangement creates individual spaces to protect delicate items from contacting each other. These multi-way compartment solutions protect the goods from damage, dust and contamination. They are easy to mount and demount and save important space when not in use.


Duraflex returnable packaging is robust and lightweight. It fits the manufacturing, storage, and transit stages. It is recommended for circular routes and frequent trips between factories, assembly sites, distribution, or repair centers. The material suits bulky, heavy parts and components and fragile goods.

Duraflex can be transformed in almost any form and design. This feature makes it one of the most cost-effective resources for customized industrial packaging. In sectors like automotive and aviation, Duraflex packaging meets strict requirements. It provides high stability, impact strength, stacking capability, and vibration resistance during transport. We design different Duraflex partitions for delicate parts. Foam padding or inserts can maximize goods protection.