BlOG PUBLISHED ON: February 2025
Advances in packaging technology are continually reshaping the way manufacturers, distributors, and end users manage their costs. One of the most impactful products is Auto Palletizer (AP) Sheets, a solution that has been proven to reduce freight, labor, and warehousing expenses for businesses. These lighter, less bulky materials are more important than ever as freight and storage costs continue to rise across industries.
Save Over 30% on Annual Costs
One of the most compelling reasons to switch from traditional corrugated sheets to AP sheets is the substantial cost savings. For many applications, AP sheets can lead to savings of up to 30% on annual sheet spend. One of our clients told us that this switch resulted in savings of over $120,000 annually for their business.
“We ran our new Badger AP sheets through extensive testing and production trials for about 18 months,” says Chad Kravick, Vice President at Badger Paperboard. “The results have been extraordinary, with our AP sheets outperforming traditional corrugated sheets in multiple aspects.”
The Advantages of Switching to AP Sheets
Beyond cost savings, the benefits of AP sheets extend to improved performance, sustainability, and packaging efficiency.
Flawless Performance in Automated Environments
One key feature of AP sheets is their operation in automated systems. “I had a distributor partner call about replacing corrugated pallet sheets with chipboard AP Sheets at a very large dog food company in Kansas City,” says Kravick. “They had been using corrugated sheets on an automatic palletizer for 10 years. I flew out and made a joint call with the rep, and we took samples of our Badger AP sheet. The sheets ran flawlessly, no multiple pick-ups, no line shutdowns.“
Improved Sustainability & Labor Efficiency
In addition to cost savings, AP sheets help reduce the carbon footprint by requiring fewer trucks for transport. They also reduce labor costs by cutting down on the number of pallets needed for unloading and storage.
Feature |
Auto Palletizer Sheets |
Corrugated Sheets |
Material |
Chipboard | Corrugated fiberboard |
Cost Savings |
$120,000+ annually for some | 30% more expensive |
Labor Costs |
Reduces labor costs (fewer pallets to load/unload) | Increases labor costs (more pallets to load/unload) |
Warehousing Space |
27 square ft. for 6,000 sheets | 293 square ft. for 6,000 sheets |
Thickness Options |
Available in almost any caliper | Typically .125″ |
Sustainability |
Reduces carbon footprint (fewer trucks on the road) | Requires more trucks to transport |
Performance in Automated Environments |
Better porosity for flawless performance in automated palletizers | Prone to multiple pick-ups and line shutdowns |
Freight & Warehousing Benefits
Here’s where AP sheets also shine: a truckload of 6,000 corrugated sheets currently takes up 22 pallets of space. In contrast, Badger Paperboard can fit the same number of chipboard AP sheets onto just two pallets. This reduction in pallet space leads to lower freight costs and better use of storage space.
Request a Free Sample Today
Looking into an alternative to corrugated products? Request a free sample of Badger’s Auto Palletizer Sheets and experience the performance firsthand. Badger is right here to help you streamline your operations and reduce costs.
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.
