Corrugated plastic — simple name, huge utility. Whether you know it as Coroplast, Corflute, twinwall, or PP hollow sheet, this versatile material quietly powers signage, packaging, agricultural solutions, and industrial logistics around the world.

In this deep-dive blog we’ll explain the many names corrugated plastic goes by, what it’s made from, how it’s made, its physical properties, typical applications, sustainability considerations, and — importantly for buyers — the production and supply capabilities of Xinsu, a manufacturer specializing in corrugated plastic sheets and corrugated plastic boxes.

1. Multiple Names, Same Material

Corrugated plastic appears under many labels depending on geography, industry, and Buyer’s Region:

• Coroplast — Originally a brand name that many people use generically (similar to how “Kleenex” is used for tissues). Common in North America.
• Corflute — A widely used name in Australia and New Zealand; again a brand-derived generic.
• PP Corrugated Sheet / PP Hollow Sheet — The industry-accurate descriptor: polypropylene-based corrugated sheets with a hollow (fluted) structure.
• Twinwall Plastic Sheet / Hollow Plastic Sheet — Describes the double-layer, hollow structure that gives the sheet strength and light weight.
• Correx / Correx Board / Correx Sheet — Another trade name used in several markets.

All of these typically refer to the same basic construction: a sheet formed from polypropylene (PP) with a fluted, hollow internal profile that provides stiffness and impact resistance at very low weight.

2. What Is It Made Of? (Material & Composition)

Base polymer: Most corrugated plastic sheets are made from polypropylene (PP) — specifically, extruded homopolymer or copolymer grades designed for sheet extrusion.

Why polypropylene?

• Selective Density — Different density weight for shipping and handling.
• Toughness — good impact resistance and durability.
• Chemical resistance — resists many solvents, acids, and bases.
• Weatherability — can be formulated for outdoor use (UV stabilizers, antioxidants).
• Recyclability — PP is widely recyclable where facilities exist.

Additives and variations

• UV stabilizers — to reduce sun-driven degradation when used outdoors.
• Anti-static additives — for electronics packaging.
• Color masterbatches — for colored or opaque sheets.
• Flame retardants — in specific industrial applications (subject to regulation).

The sheet’s fluted core — parallel channels formed during extrusion — is what gives corrugated plastic its structure: the outer skins carry bending loads while the internal flutes provide separation and stability.

3. How It’s Made — Basic Production Process

The core manufacturing method is sheet extrusion followed by cooling and cutting. Typical steps:

1. Raw material preparation — polypropylene resin (pellets) is blended with additives (UV stabilizers, colorants).
2. Extrusion — blended pellets feed into an extruder; a specially designed die forms the twinwall/fluted profile in a continuous sheet.
3. Calibration & cooling — the hot sheet passes through cooling/calibrating rolls to set thickness and flatness.
4. Cutting & trimming — sheets are cut to desired widths and lengths. (Many factories can produce continuous/unlimited length rolls or very long sheets.)
5. Printing & finishing — flexographic or digital printing systems print logos, graphics, or security marks. Additional post-processing such as creasing, folding, or die-cutting produces custom boxes and displays.
6. Quality control — checks for thickness, density, print registration, and visual defects.

This efficient, continuous process makes corrugated plastic an economical choice for medium- and large-volume production.

4. Product Physical Properties — What Makes It Useful

4. Product Physical Properties — What Makes It Useful

Corrugated plastic combines a handful of physical properties that make it uniquely suitable across many industries:

• Lightweight — very low mass compared to wood or solid plastic panels, reducing shipping costs.
• High stiffness-to-weight ratio — the fluted structure resists bending and distributes loads.
• Impact resistance — can take knocks and returns to shape, making it ideal for reusable packaging.
• Waterproof & chemical resistant — unaffected by moisture and many chemicals, unlike paper-based boards.
• Thermal tolerance — usable across a broad temperature range; extreme cold or heat may require specification checks.
• Printable surface — supports high-quality printing for signage and displays (flexo, screen, UV digital).
• Customizable thickness — commonly ranges from thin liners suitable for signage to thicker panels for boxes and partitions.
• Foldable / creasable — with proper creasing, panels can be folded into compact, space-saving boxes (very useful for storage/return logistics).

Typical thicknesses seen in the industry vary, and Xinsu specifically offers 1.6 mm to 12 mm thickness ranges (more detail in the Xinsu section below). Sheet width capability and customizable length give manufacturers and customers broad design freedom.

5. Applications — Where Corrugated Plastic Shines

Corrugated plastic is a multi-purpose material used in many sectors:

1. Advertising & Signage

• Outdoor yard signs (political campaign signs, real estate signs)
• Point-of-sale displays and exhibition boards
• Promotional signage with full-color printing

2. Packaging & Logistics

• Lightweight reusable transit boxes and partitioning for parts
• E-commerce packaging inserts and protective layers
• Pallet slip sheets and container liners

3. Industrial Uses

• Corrosion-resistant protective skins
• Temporary floor protection in construction or renovation
• Electrostatically safe panels (with anti-static formulations) for electronics handling

4. Agricultural & Horticultural

• Seedling trays, protective covers, and greenhouse partitioning
• Nursery bags and containers (lightweight, waterproof)

5. Food & Cold-chain Uses

• Insulated or lined boxes used in chilled seafood transport — works well with ice-packed logistics when combined with appropriate insulation. (Corrugated plastic remains dimensionally stable in low temperatures and resists water.)

6. DIY & Architectural

• Temporary partitions, craft uses, model building, and architectural mock-ups

7. Specialized Applications

• Bottle-layer coroplast sheets used as separators and shock-absorbing layers in packaging (mentioned in product contexts).

Because it’s printable, waterproof, and tough, corrugated plastic often replaces corrugated cardboard where moisture or reuse is a concern.

6. Design & Printing — Branding Meets Durability

Corrugated plastic accepts a wide range of printing technologies:

• Flexographic printing — common for high-volume, repeatable color work.
• UV digital printing — high-resolution printing for detailed graphics, shorter runs, and personalization.
• Screen printing — used for spot colors and heavy inks.

Designers love corrugated plastic because full-color branding stays vibrant outdoors when UV-stable inks and topcoats are used. For packaging, creasing and die-cut patterns enable complex, foldable box geometries that collapse flat for storage — a major logistical win.

7. Sustainability & Recycling

Corrugated plastic is often recyclable as polypropylene (PP). However:

• Recycling availability depends on local municipal or industrial recycling streams.
• Printed or contaminated sheets may need separation or special handling.
• Increasingly, manufacturers offer recycled-content options and programs to take back used sheets.

Compared to single-use corrugated cardboard, corrugated plastic can be re-used many times, offering a potentially lower environmental impact if reuse and end-of-life recycling are achieved.

8. Xinsu — Production & Supply Capacity (What Buyers Need to Know)

You asked specifically for Xinsu’s production and supply capacity — here’s a clear, buyer-focused overview based on Xinsu’s real capabilities:

Product range

Xinsu manufactures a broad range of corrugated plastic products, including:

• Corflute / Coroplast sheets — for signage and printing.
• Correx-style boards — for heavy-duty printed materials and industrial applications.
• Corrugated plastic boxes and foldable packaging solutions — designed to save storage space and improve return logistics.
• Specialized sheets for bottle-layer separators and protective packaging.

Customization & size capabilities

• Width: up to 2600 mm — enabling large-format panels without seams for signage or industrial needs.
• Thickness range: 1.6 mm to 12 mm — covering thin signage sheets to rigid partitioning and box panels.
• Length: effectively unlimited in continuous production — sheets or rolls can be produced to customer-specified lengths for seamless production workflows.

These dimensional capabilities let Xinsu fulfill orders for very large displays, long continuous panels, and a wide range of packaging geometries.

Production scale & flexibility

• Xinsu operates with industrial extrusion lines designed for continuous sheet production and downstream finishing (cutting, printing, creasing, die-cutting).
• The factory focuses on customized runs as well as stable, repeatable batch production, supporting both low-volume prototypes and medium-to-high volume commercial orders.
• Because Xinsu’s equipment supports in-line printing and finishing, many customers benefit from faster lead times and single-stop manufacturing (sheet → print → die-cut → box).

Note: To ensure transparency, if you need exact monthly/weekly throughput numbers, MOQ thresholds, or delivery lead times for a specific SKU or printed job, Xinsu’s sales team can provide a tailored production schedule and capacity plan based on current factory load and order specifics.

Quality control & consistency

• Xinsu’s processes emphasize thickness calibration, visual inspection, and print registration control, ensuring consistent product quality across long runs.
• Typical controls include measurement of material thickness, flatness checks, and print color consistency testing.

Packaging & logistics approach

• For corrugated plastic boxes and foldable products, Xinsu offers flat-pack shipping to reduce volume in transit and storage for buyers — an advantage many customers cite for lowering logistics costs.
• The material’s moisture resistance reduces the need for secondary protection during shipping in many cases.

9. Choosing the Right Corrugated Plastic Product

If you’re selecting corrugated plastic for a project, consider these practical criteria:

• Thickness & rigidity needs — heavier loads and repeated reuse require thicker panels (toward 12 mm); signage and lightweight packaging can use 1.6–4 mm.
• Print quality & outdoor exposure — specify UV-stable formulations and inks for long-term outdoor signage.
• Folding & creasing requirements — ask for creasing allowances if you need foldable boxes.
• Chemical & temperature exposure — confirm the PP grade and additives if the product will face aggressive chemicals or extreme cold.
• Recyclability goals — decide if recycled-content resin is desirable and check regional recycling options.

Xinsu can consult on these choices and produce samples for evaluation before a full production run.

10. Practical Use-Cases & Case Examples

• Political yard signs: Lightweight, printable, and easy to mount — widely used during campaign seasons.
• Cold-chain seafood boxes: When combined with insulating liners, corrugated plastic boxes perform well in wet, cold environments and survive handling in chilled logistics.
• Reusable parts packaging: Automotive or electronics manufacturers use corrugated plastic partitions and trays because they endure multiple cycles.
• Foldable nursery boxes & nursery bags: Waterproof, lightweight, and space-saving — great for plant nurseries and greenhouses.

11. Common FAQs (Quick Answers)

Q: Is corrugated plastic waterproof?
A: Essentially yes — polypropylene repels water and retains structural integrity when wet.

Q: Can it be used outdoors permanently?
A: Yes — if UV stabilizers and outdoor-grade inks are specified. Otherwise, prolonged sun exposure can cause fading and gradual embrittlement.

Q: Can corrugated plastic be recycled?
A: The material (PP) is recyclable, but you must check local facilities for PP sheet acceptance. Reusing the panels multiple times before recycling is often the most sustainable choice.

Q: Can Xinsu print my logo and ship ready-to-use boxes?
A: Yes — Xinsu supports in-line printing and finishing to deliver branded, die-cut, and folded products ready for use.

12. Conclusion — Why Corrugated Plastic Is a Smart Choice

Corrugated plastic is a low-weight, tough, waterproof, and printable material that fills a niche between paperboard and solid plastics. Its versatility is why it’s called many things (Coroplast, Corflute, twinwall) — but whichever name you use, the benefits are the same: economical production, long life with reuse, and excellent performance where moisture, durability, and printability matter.

For buyers and specifiers, Xinsu presents a compelling partner: wide sizing capability (up to 2600 mm width, 1.6–12 mm thickness, unlimited length options), in-house finishing and printing, and flexible production to support packaging, signage, and industrial needs. If you’re looking for foldable corrugated plastic boxes that reduce storage volume, printed outdoor signage, or specialized industrial sheets (e.g., bottle-layer separators), Xinsu has the technical scope to deliver and iterate quickly.