Paperboard Sheets for Feed Mills and Grain Operations

Each milling operation faces daily challenges when it comes to protecting materials during storage and shipment. Whether you’re operating a feed mill, grain mill, or specialty milling facility, the risk of damaged product can impact your revenue and customer satisfaction. At Badger Paperboard, we understand that moisture is your biggest enemy—and that finding the right protective solution shouldn’t slow down your production line.

The Critical Factor: Automatic Palletizing Equipment Compatibility

Modern milling operations depend on automatic palletizing equipment to maintain production speeds and control labor costs. However, this equipment requires precise specifications to function reliably.

Common Equipment Issues 

Multiple Pickups: When sheets stick together, palletizing equipment picks up multiple sheets at once, disrupting timing and creating gaps in protection. This typically occurs when sheets are too thin, have excessive static buildup, or feature incompatible surface characteristics.

Pickup Failures: Equipment that cannot consistently grab individual sheets forces production line stops and requires manual intervention. 

Production Line Shutdowns: Equipment malfunctions due to incompatible sheet specifications can halt entire production lines, creating delays and manual workaround requirements.

The Solution: Systematic Sampling and Testing

The most effective way to address equipment issues or concerns is to test sample products with your specific equipment before committing to a full order. This hands-on approach allows you to evaluate performance in real-world conditions with your exact setup.

What works perfectly in one environment might not perform the same way in another. By testing samples directly on your equipment, you can identify potential compatibility issues early and ensure the product will work reliably with your product or equipment. 

Pallet Sheets

Pallet Sheets between .018 and .028 caliper, available in chipboard or solid fiber, are a great match for protecting milling products. These sheets offer the perfect balance of protection, cost-effectiveness, and equipment compatibility that most milling operations require.

Why Pallet Sheets Work for Milling Operations 

Pallet sheets are placed directly on top of pallets before products, such as 50-pound bags, are loaded. Pallet sheets prevent damage from:

• Protruding nails that can puncture bags
• Pallet gaps that create weak spots during forklift handling
• Moisture transfer from pallet materials

The key advantage of pallet sheets is their versatility. The smooth surface works reliably with automatic palletizing equipment while providing the barrier protection your products need. Since lower caliper sheets cost less, using the thinnest material that still provides adequate protection maximizes your protection from moisture. 

Push-Pull Sheets: Specialized Protection for Super Sack Operations

Super sack operations, those handling single large bags per pallet, require a different approach. Push-pull sheets partner well with super sack operations, providing a smooth surface that protects the large product bag during loading, unloading, and storage.

Benefits of Push-Pull Sheets

Push-pull sheets have multiple benefits when paired with a super sack product: 

• Smooth Surface: Reduces friction and prevents the bag from catching on a pallet during positioning and removal.
• Saves space: Occupies less space in the warehouse and the production line, while also reducing the number of trips personnel need to take.
• Product Protection: Provides a clean, durable base for your product, eliminating the need for a traditional pallet.

The key to a successful push-pull sheet is customizing the specifications to your super sack’s weight and dimensions. The sheet caliper must match your load weight; if it’s too thin, you risk punctures during handling, and if it’s too thick, you’re paying for protection you do not need. 

Advanced Solutions: AP Sheets 

While plain chipboard handles many milling applications, certain operations benefit from Badger’s specialized paperboard options:

AP Sheets (Automatic Palletizer Sheets)

Our Automatic Palletizer (AP) sheets represent the lighter alternative to corrugated pallet sheets, specifically designed to work seamlessly with automatic palletizers while delivering cost savings, space efficiency, and protection. These sheets have been tested on automatic palletizers across the country, proving their reliability in high-volume automated operations.

The AP Sheet Advantage:

• Cost Savings: Up to 25-30% less expensive than corrugated alternatives (depending on location)
• Space Efficiency: A truckload quantity (6,000 sheets) fits on just two pallets vs. significantly larger space requirements for corrugated
• Shipping Savings: Reduced freight costs due to compact shipping profile
• Warehouse Efficiency: Minimal storage space requirements compared to bulky corrugated options
• Equipment Compatibility: Enhanced surface characteristics designed specifically for automatic palletizing equipment

Pro Tip: Avoid Caliper Overkill

One of the most common mistakes we see in milling operations is using sheets that are thicker and more expensive than necessary. Many operations default to corrugated sheets or higher calipers “just to be safe,” but this creates unnecessary costs without providing additional protection.

The smarter approach: Use the lowest caliper that provides adequate protection and works reliably with your automatic palletizing equipment. Since lower caliper sheets cost significantly less, right-sizing your sheet specification can generate substantial savings without compromising product protection.

That’s where Badger’s sampling process becomes valuable. We’ll help you identify the minimum effective caliper for your operation.

Get Started with the Right Solution

At Badger Paperboard, we’re committed to understanding your needs and providing exactly the right solution—not too little, not too much, but precisely what your milling operation requires to protect your product. 

Request a free product sample to test with your automatic palletizing equipment, or contact us to discuss any questions you may have. Our team will help you identify the optimal caliper and material for your operation.