How to choose grammage and number of layers in paper packaging

Three variables determine protection in paper packaging: the grammage of the paper (weight per square metre), the number of wrapping or filling layers and the quantity used. For light products, low grammage and a single layer are enough, while for fragile and heavy products it is often more efficient to add layers than to increase grammage. The exact value comes from a drop and shipping test with your product.

What does grammage change?

As grammage (g/m²) rises, paper becomes more rigid and tear-resistant, but wrapping flexibility drops and rolls get heavier. In shaped papers such as the honeycomb-textured SafePak®, protection comes less from grammage than from the texture spreading the impact.

What does the number of layers change?

Each layer absorbs some of the impact before passing it to the next. For most fragile products, two thin layers give a better result than one thick layer, and they also fit the shape of the product better.

A starting point by product type

The values below are a starting point; the exact set-up is confirmed by a drop test.

How to run a drop test

1. Pack the product with your chosen layers and void fill.
2. Drop the carton from waist height onto a flat floor, landing on a corner, an edge and a face in turn.
3. Inspect the product and the inner packaging; if there is damage, increase the number of layers first, then the amount of void fill.
4. Send the same set-up by a real courier and record the result.

Verify with samples

Biyopak sends samples to suit your product; you can try different layer and grammage combinations in the same carton and find the best protection for the least paper. Request a sample.