BlOG PUBLISHED ON: July 2026
Ask 10 people what makes a paperboard sheet “good,” and you’ll probably get 10 different answers. Some care about strength. Some care about how it holds up to moisture. Some just want their suction cups to grab one sheet at a time instead of three. Here’s the truth: for most applications, you don’t need a coating at all. An uncoated sheet, like plain chipboard or solid fiber, does the job well and keeps your costs where they belong: down. Coatings earn their place when a specific challenge calls for them.
The Badger Team put this guide together to walk you through the most common substrate and coating options, what each one is built for, and how to figure out which one belongs in your operation.
Plain Chipboard (and Solid Fiber): The Right Starting Point for Most Applications
Plain chipboard and solid fiber are the most economical options in the lineup. Neither carries a coating, and for the vast majority of applications, neither needs one. Both substrates are available across Badger’s pallet sheets line, so whether you’re using sheets as dividers, separators, or general-purpose protection between products on a pallet, an uncoated option gets the job done without adding costs you don’t need.
Automatic Palletizer (AP) Sheets: Built for Automation
AP sheets are another substrate that performs without a coating. Its porosity is engineered to let suction cups pick up one sheet at a time, which cuts down on multi-picks and keeps automated lines moving. It’s also less expensive than corrugated and takes up less warehouse space, so high-volume, automated settings get reliable performance without paying for extras they don’t need.
Polycoated: Built for Moisture and Grease
When water, grease, or oil are part of the equation, polycoated sheets step up. This coating creates a barrier that keeps moisture and grease from soaking through, which makes it suitable for food packaging applications. Polycoated is available as one of the substrate options across Badger’s pallet sheet line.
Virgin Kraft: Strength and Reusability for Push-Pull and Tier Sheets
Virgin kraft isn’t about a surface coating; it’s about the long, strong virgin fibers themselves. That tensile strength is exactly why virgin kraft is the substrate behind push-pull sheets, which need to hold up through repeated handling, and tier sheets, which can be reused time and time again without tearing, softening, or losing their shape.
Bending Chipboard: Clean Folds, Every Time
If your application calls for folding into cartons or partitions, bending chipboard is designed to hold a crisp shape without cracking. It’s still made from 100% recycled material, so you’re not sacrificing sustainability for durability.
Solid Bleached Sulfate (SBS)
SBS sheets offer a smooth look and can be ordered coated on one side, coated on both sides, or left uncoated, depending on what your product needs. This makes SBS a popular choice for food packaging and cosmetics applications. You can see where SBS fits alongside Badger’s other options on the materials page.
Clay Coated: Tough, Clean, and Water-Resistant
Clay-coated sheets are made from 100% recycled material and bring water resistance along with a clean, finished edge. If you need pads or sheets that look sharp and hold up to moisture, this is a solid middle ground between an uncoated sheet and a premium finish like SBS.
Anti-Slip Coating: Stability Without the Slide
This one is a category of its own. Anti-slip sheets feature a coating engineered for a high coefficient of friction, so products stay put during handling and transport instead of shifting on the pallet. Badger’s version is tested to withstand a 30-degree angle of slide and is available coated on one or two sides. It’s also recyclable and reusable, so you’re not trading stability for sustainability.
Specialty Grades: When You Need Something More Specific
Some applications call for a substrate outside the standard lineup. If none of the above feels like a perfect match, the Badger Team can talk through specialty paperboard grades built around your exact application.
So, Which One Is Right for You?
- Just need a reliable, economical option? Start with plain chipboard or solid fiber. Most applications don’t need a coating at all.
- Running an automated line and need consistent sheet pick-up? AP sheets are designed for exactly that, without the extra cost of a coating.
- Shipping products that need to resist water and grease, including food packaging applications? Look at polycoated.
- Need strength and reusability for push-pull handling or tier sheet applications? Virgin kraft’s long fibers are built for it.
- Need a premium appearance for food packaging or cosmetics applications? SBS is worth exploring.
- Fighting product shift on the pallet? Anti-slip is built for exactly that.
The right substrate depends on what your product is, how it’s shipped, and what kind of damage you’re trying to avoid. That’s a lot of variables, and you shouldn’t have to sort through them alone.
Talk to the Badger Team
Every one of these substrates is available cut to your specs, and Badger’s nationwide facilities mean a quote lands in your inbox fast, often within 24 hours. If you’re not sure what fits your application, request a material sample and see (and feel) the difference for yourself.
As always, it’s our goal to make everyone a Badger fan.
About Badger Paperboard
Badger Paperboard is a leading custom paperboard converter specializing in high-quality packaging and shipping materials. With over 30 years of industry expertise, we pride ourselves on delivering paperboard sheets, pads, and guards that are cut precisely to your specifications and delivered on time.
As the nation's top supplier of paperboard products, we serve customers from Maine to California and everywhere in between. With facilities strategically located across the country, we ensure fast turnaround times and exceptional customer service, no matter where you're based.
