ProPac Tools — Flexible Packaging
Honeycomb Paper Roll Calculator
Calculate output metres, number of rolls, raw material cost & profit — from a single kraft paper input roll.
What is Honeycomb Paper (Cushioning Wrap)?
Honeycomb paper — also called paper bubble wrap or honeycomb cushioning wrap — is an eco-friendly alternative to plastic bubble wrap. It is made from a single sheet of kraft paper that is die-cut with staggered slits and then expanded to form a hexagonal honeycomb pattern. The expanded roll provides excellent cushioning, void-fill, and surface protection.
Unlike multi-layer corrugated board, honeycomb cushioning wrap is a single-layer product. The magic is entirely in the cut-and-expand process — no lamination, no glue, no heat required.
📦 Material
Kraft paper — 40 to 80 GSM. Lighter GSM = more metres per kg. Heavier GSM = stronger cushioning.
⚙️ Process
Die-cut slits → mechanical expansion → rewinding onto output cores. Speed: 30–200 m/min depending on machine.
🌿 Application
E-commerce wrapping, fragile goods, jewellery, glassware, ceramic tiles, auto-parts — any item needing surface protection.
How is Output Calculated?
The core formula is simple — but many manufacturers get it wrong due to unit mismatch:
Expanded Length (m) = Flat Paper Length × Expansion Ratio
Usable Length (m) = Expanded Length × (1 − Wastage % / 100)
Output Rolls = floor ( Usable Length ÷ Output Roll Length )
Roll Weight (kg) = Usable Paper Weight ÷ Number of Rolls
Worked Example
| Input Parameter | Value | Result |
|---|---|---|
| Roll weight | 50 kg = 50,000 g | — |
| GSM × Width | 60 × 0.3 m = 18 | — |
| Flat paper length | 50,000 ÷ 18 | 2,778 metres |
| After expansion (1.8×) | 2,778 × 1.8 | 5,000 metres |
| Usable (8% wastage) | 5,000 × 0.92 | 4,600 metres |
| Output rolls (50 m each) | 4,600 ÷ 50 | 92 rolls |
| Roll weight | 46 kg ÷ 92 rolls | 0.5 kg per roll |
Expansion Ratio — What Does It Mean?
The expansion ratio tells you how many times the final expanded roll is longer than the original flat paper. A ratio of 1.8× means 1 metre of flat kraft paper becomes 1.8 metres of honeycomb wrap after expansion.
| Ratio | Cell Size | Best For |
|---|---|---|
| 1.5× | Tight / small | Heavy items, strong wrapping needed |
| 1.8× | Standard | General e-commerce packaging (most common) |
| 2.2× | Wide | Light fragile items, jewellery, glassware |
| 2.5× | Maximum | Very light goods, maximum yield per kg |
Choosing the Right GSM for Kraft Paper
GSM (Grams per Square Metre) is the key variable that controls both the strength of your product and the number of metres you get per kilogram of input paper.
| GSM | Metres per kg (300mm wide) | Recommended Use |
|---|---|---|
| 40 GSM | 83.3 m/kg | Lightweight items only |
| 50 GSM | 66.7 m/kg | Light e-commerce |
| 60 GSM | 55.6 m/kg | Standard — most popular |
| 80 GSM | 41.7 m/kg | Heavy goods, fragile items |
| 100 GSM | 33.3 m/kg | Export, premium cushioning |
| 120 GSM | 27.8 m/kg | Heavy industrial packaging, auto parts |
| 140 GSM | 23.8 m/kg | Maximum strength — heavy machinery, export heavy goods |
Who Uses This Calculator?
Plan raw material purchase per production shift
Calculate how many rolls needed per 1,000 orders
Price per roll vs raw material cost analysis
Verify supplier quotes against actual output
