Custom Cardboard Sheets Cut to Your Size

What are cardboard sheets?

Cardboard sheets are the simplest item we make. They are flat panels of corrugated board, cut square to the size you ask for, with no folds, flaps or slots.

That simplicity is the point. A sheet goes wherever you need a stiff, light layer: between rows of goods, under a print, across a floor. Our photos show a stack of brown kraft sheets beside the boxes they are often used with.

They belong to our box inserts and packing supplies, and every order is cut to measure.

Which board thickness should I choose?

Think about what the sheet must do. A backing board for a print needs to be flat and thin. A pallet layer pad needs to spread weight. A floor cover needs to take boots and dropped tools.

Our corrugated flute guide for buyers explains each flute in more depth.

How do I work out the sheet size?

For a box liner, measure the inside length and width of the box base. Take 2 to 3 mm off each side so the sheet drops in without bowing.

For a pallet layer pad, measure the footprint of the boxes, not the pallet. If the boxes overhang slightly, size the pad to the boxes. If they sit inside the pallet edge, size it to the pallet.

For backing boards, add a few millimetres to the print on every side. That way the edges of the print never reach the edge of the board.

How do layer pads help on a pallet?

A pallet is built in layers, and each layer sits on the tops of the boxes below. Without a pad, the weight lands only on the box edges. Boxes that are not lined up perfectly can then tip or crush.

A flat sheet between layers spreads the load across every box top. It also ties the layer together, so a single box is less likely to slip out. On the top layer, a sheet gives straps and film a flat surface to grip.

For the corners, add our cardboard edge protectors for pallets. Together, sheets and angles make a square, stable load.

Can cardboard sheets be printed?

Yes. Most sheets are left plain, but print is useful in a few cases. A box liner can carry a logo or a short note that the customer sees on opening. A floor cover can show your company name on site.

We print one colour, two colour or full colour CMYK, on kraft board or on board with a white face. Our designers set up artwork at no charge and send a digital proof for approval first.

Can I use cardboard sheets to post flat items?

Yes, and this is one of the most common small orders. Prints, certificates, photos and calendars all bend easily in the post. Two sheets, one each side, keep them flat.

Cut the sheets a little larger than the item, then tape the edges so it cannot slide out. Slip the bundle into a flat mailer or an envelope. For anything framed, use a proper box and corner protection instead.

E flute is the usual pick here. It is thin enough to keep the parcel slim, but stiff enough to stop a crease. For a ready-made option, our slim flat cardboard boxes do the same job in one piece.

Which mistakes should I avoid?

Ordering sheets to the exact inside size of a box is the most common slip. The sheet catches on the walls and bows in the middle. A small allowance fixes it.

Choosing board that is too thin for the job comes next. E flute is lovely for a print, but it will not spread the weight of a full pallet layer. Match the flute to the load.

Lastly, damp is the enemy of every board. Sheets left in a cold van or an open yard soften quickly, so keep them dry until use.

Do you also make the boxes?

Yes. Many customers order sheets alongside cartons, so the liners and the boxes match in size from the first delivery. If your sheets are for a box we make, tell us the box reference and we size the sheets to it.

Ordering both together also keeps things simple at goods-in. One delivery, one set of sizes, and no need to trim sheets by hand with a knife on the packing bench.

For plain brown cartons to go with them, see our plain cardboard boxes made to size.

How do I order cardboard sheets?

Sheets are priced from £0.25 per unit, and the exact price comes on your written quote. Send us the length, width, board and quantity, plus any print. Use our online trade quote request, email info@ordercardboardboxes.co.uk, or send a WhatsApp.

Printed sheets come with a free digital proof. We cut and print in 4 to 6 business days from approval. Tracked delivery follows in 2 to 3 business days, free to wherever you are in the UK. If a delivery arrives damaged or misprinted, photos within 10 days get it reprinted or refunded.