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FEFCO 0940

Dual-Column Folded Cushion Pad

This heavy-duty interior buffer rolls inward to form two raised, shock-absorbing columns. Designed to sit inside a master shipping box, it suspends heavy, fragile, or irregularly shaped products safely away from the outer walls.

Because it relies entirely on straight parallel creases, this pad avoids shaped cutting. That simplicity is traded for a large overall board footprint and the manual labor required to roll the columns at the packing bench.

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  • Order custom samples, short runs, or production runs.
  • US-based. Nationwide service.
  • Nationally competitive pricing & delivery costs.
  • Available in a wide variety of configurations.

At a glance

  • Forms two parallel tubular columns for heavy-duty shock absorption
  • Suspends central payloads or levels deep voids inside a master carton
  • Requires manual two-handed folding against board tension

Common uses

  • Suspending motors or pumps between two raised columns
  • Leveling unloaded armrests for upholstered furniture shipping
  • Top and bottom caps for hazardous liquid transport
  • Replacing molded EPS foam blocks

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Payload Suspension and Void Leveling

Suspending heavy central payloads

The dual columns cradle products with protruding centers, isolating them from impact. This makes it an effective, recyclable alternative to molded EPS foam blocks for heavy items.

Leveling irregular shapes for outer wrapping

Used frequently in furniture shipping to level unloaded armrests or uneven profiles so stretch film or outer cartons sit flush without tearing.

Top and bottom impact isolation

Positioned above and below internal grid separators, the thick rolled columns provide massive vertical crush resistance for fragile goods.

Replacing molded EPS foam blocks

For heavy industrial goods, the five overlapping layers of corrugated board offer comparable shock absorption to foam, while remaining fully curbside recyclable.

Industrial, Furniture, and Hazardous Goods

Industrial and mechanical parts

Pumps, motors, and heavy assemblies require rigid standoff protection to prevent shifting. The dense rolled columns absorb significant kinetic energy.

Hazardous materials and glass transport

Used as top and bottom caps to sandwich grid separators, preventing vertical crush damage to chemical or beverage bottles during rough transit.

Upholstered furniture shipping

Furniture with asymmetrical profiles often needs deep void fill before wrapping. This pad levels the surface so outer protective layers apply evenly.

Reviewing Simpler Pads or Perimeter Buffers

High-speed fulfillment lines

If your packing line cannot accommodate the time required to manually roll ten parallel creases, a pre-glued insert or a simpler drop-in pad will keep operations moving faster.

Perimeter protection needs

If the goal is to protect the outer edges of a square product rather than suspending a central item, a perimeter wrap is often a more direct fit.

Basic layer separation

If you only need to separate flat items or reinforce a box bottom, a standard uncreased flat pad uses significantly less material and requires zero assembly.

Board Thickness, Blank Size, and Assembly Labor

Balancing board grade with folding fatigue

Heavy double-wall board provides extreme shock absorption but drastically increases the physical effort required to roll the columns. Single-wall B or C flute often provides the best balance of column strength and operator ergonomics.

Accounting for blank sprawl

The flat, unfolded pad is massive because the side columns require five overlapping layers of board. This high material usage should be weighed against the simplicity of straight-line production.

Master carton fit

The pad relies entirely on the walls of the outer shipping box to prevent the rolled columns from springing open. The pad dimensions must be precisely matched to the master carton's internal clearance.

Packing line speed and manual assembly limits

Operators must hold the corrugated board against its natural spring-back tension through four consecutive parallel folds per side. Assess whether your fulfillment team has the time and space for this two-handed assembly.

Adjusting Column Depth, Central Clearance, and Locking Features

Column depth and void volume

The height of the cushioning columns can be extended for deeper shock absorption, though this directly increases the total flat board size.

Central gap width

The flat floor between the two columns can be widened or narrowed to exactly match the width of the suspended product.

Adding locking tabs to reduce spring-back

While the standard design relies on friction and the outer box, locking tabs can be added to hold the columns closed. This shifts production from simple straight cuts to shaped flatbed routing.

Board and packing details

Straight-line production limits

The efficiency of this pad relies on using only straight, parallel creases. Adding finger holes or relief cuts will require shaped cutting.

Additional notes

Two-handed manual folding requirement

Operators must hold the corrugated board against its natural spring-back tension through four consecutive parallel folds per side before inserting it into the master carton.

Related Internal Buffers and Pads

0900: Flat Pad

Look at this option if you only need a simple layer divider or bottom reinforcement without raised cushioning.

0929: C-Channel Buffer

Look at this option if you need a simpler, single-fold side standoff that requires less manual folding labor.

0904: Perimeter Wrap

Look at this option if the product requires protection around its outer edges rather than central suspension.

FAQs

Assembly and Packing

Does this pad hold its shape outside of the box?

No. The rolled columns rely on the friction of the corrugated board and the rigid walls of the master carton to stay closed. If removed from the box, the tension of the board will cause the columns to unroll.

Can this insert be assembled automatically?

Standard linear folder-gluers cannot pre-assemble this pad, and the opposing multi-roll folds make it highly resistant to standard robotic insertion. Plan for manual assembly at the packing bench.

Material and Production

Why does this pad use so much material?

To create the hollow, load-bearing columns, the board must roll inward five times on each side. This overlapping creates incredible vertical strength but requires a flat blank much wider than the final assembled footprint.

Comparison

Is this the same as a standard flat pad?

No. While the term 0940 is sometimes used loosely in the market for any flat piece of cardboard or EPS foam, the actual engineered corrugated standard is this specific 11-panel rolled buffer.

Material and Production

What board thickness makes the most sense for this design?

Single-wall B or C flute is usually the most practical choice. While double-wall board offers massive cushioning, the spring-back tension makes it ergonomically difficult for operators to fold by hand.

Comparison

How does this compare to molded EPS foam?

It provides comparable heavy-duty shock absorption for industrial goods while remaining fully curbside recyclable. However, it requires significant manual folding labor, whereas foam blocks drop right into the box.

Adjustments

Can we add finger holes or locking tabs?

Yes, but modifying the straight-line design with cutouts or tabs shifts the production method to shaped flatbed routing, which changes the manufacturing approach.

Assembly and Packing

How is the product loaded into this buffer?

The product is typically placed into the central recessed floor, suspended between the two raised columns. The entire assembly is then lowered into the master carton, or the pad is built directly inside the box before loading.

A highly effective shock absorber that trades material density and manual packing effort for extreme vertical and lateral protection.

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