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Crate liner projects usually start with a spreadsheet of dimensions and end with disappointment when a stock panel gets trimmed to fit. Flutes run the wrong way, cut edges fray, fastener holes crack the walls, and the 'liner' becomes an insert that shifts, bulges and ages badly. We cut corrugated sheet liners to specification instead: every panel, divider and corner piece is produced from your crate drawings, with flute orientation, tolerances and finishing decided before the first sheet is fed.
Flute direction is the detail most suppliers ignore. In a crate floor, flutes running with the travel direction give flexural stiffness under point loads; in wall panels, flutes placed vertically resist bending along the panel height; in dividers, orientation decides whether a 400 mm span bows under side pressure. Because we extrude and convert our own PP hollow sheet, we choose direction per component rather than accepting whatever the warehouse had in stock.
Edge quality follows from tooling. Sheets are die-cut on matched tooling rather than slit with worn blades, so cut edges stay clean and closed - important because open flutes wick moisture and collect dust in washdown or outdoor loops. Where the design demands it, edges are welded, capped or folded to seal the flutes completely, and corner reliefs are pre-cut so panels sit square against crate radii.
Material specification is documented per panel. Thicknesses run from 2 to 12 mm, GSM from 250 to 3500, with corona treatment above 46 dyne/cm where labels or print must adhere. Conductive and anti-static grades protect electronic work-in-process; UV-stabilised grades serve crates that live on yards and docks. Every liner kit ships with a spec sheet listing grade, gauge and treatment per part, so purchasing can re-order without archaeology.
Assembly logic is part of the package. Liner kits arrive as labelled sets - floor, four walls, lid insert, dividers - with fastener positions matching your crate mouldings, so fitting takes minutes on the line, not improvisation with a knife. Replacing a damaged panel is a one-part order, not a full kit purchase.
Testing covers the way crates actually travel. Assembled liners are checked for panel deflection under stacked load, corner integrity after repeated insertion cycles, and dimensional stability across the -20 to +60 degree service range. Kits for electronics lines get surface-resistance verification on the finished liner, not just the resin certificate.
Current production serves precision plastic crate programs for automotive electronics, instrument transport cases, after-market spare-part crates and cleanroom-adjacent component handling. Orders range from pilot kits of a few dozen crates to recurring schedules supporting distribution networks across Europe and North America.
Lead time stays short because conversion is in-house. A new liner kit moves from drawing approval to first articles in roughly two weeks; repeat orders ship against blanket schedules. Drawing changes - a new divider pitch, an extra sensor cut-out - are tool edits, not new projects.
If stock-panel liners are causing fit problems, edge frays or moisture ingress, send us one crate drawing and one failed liner. We will return a cut-to-spec proposal with flute direction per panel, edge treatment options and a unit price per kit - usually within a week.
