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FEFCO 0946

Dual-Column Corrugated Cushion Pad

  • Available in a wide range of custom configurations & material selection.
  • Order 1 sample. Or order 100K+ units. Or anything in between.
  • Affordable delivery across North America.
  • Design support, warehousing, testing, assembly available.
  • Widest machinery capability in America via 30+ specialist partner plants.
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Product details

Top highlights

  • Replaces EPS foam for heavy industrial parts and fragile goods
  • Produced through straight parallel scoring without complex cuts
  • Requires two-handed manual folding and an outer master carton

About this product

The dual-column cushion pad is a heavy-duty corrugated insert designed to replace EPS foam. It rolls from a single flat sheet into two closed tubular columns connected by a flat base, creating a secure central channel to cradle dense or fragile products.

Because it uses straight parallel creases, it can often be produced through simple scoring. However, that production advantage must be weighed against the manual labor required to fold the tubes and hold them closed while loading them into a master carton.

Common uses

  • Automotive parts like seatbelt pretensioners
  • Heavy electronics and motors
  • Glass or porcelain group packaging

Get a quote

Share what you know. We'll take it from there. Or email us at info@herculeindustrial.com

Best Price Guarantee

Already have a packaging quote? Let us beat it.

Send us the quote you have. We will beat it for the same specifications, quantity, and delivery requirements.

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Free quote review. No obligation.

30+specialist partner plants

We supply through the plant best suited to your price, material, production, and delivery requirements.

Why we can beat a lower quote

30+ plants give us more ways to lower the price.

Each plant has different machinery, material costs, order minimums, and freight rates. Our buying volume helps us secure better pricing. We then quote through the plant that gives you the lowest total price for your requirements.

Send us your current quote. Watch us beat it.

Attach it to the quote form or email it to us. We'll review it free and send you our price.

Upload a competing quoteinfo@herculeindustrial.com
Best Price Guarantee terms

To qualify, send a written supplier quote dated within the past 30 days and addressed to your company. It must cover the same dimensions, construction, material, print, finish, quantity, tooling, freight, delivery date, and delivery location. The guarantee does not cover taxes, expired quotes, liquidation or clearance sales, or obvious pricing errors.

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Heavy-Duty Bracing and Foam Replacement

EPS foam replacement for dense components

For heavy items like motors, pumps, or automotive parts, the dual rolled tubes provide massive vertical and lateral crush resistance. The central channel suspends the product away from the outer box walls, offering foam-like shock absorption using fully fiber-based corrugated board.

Group packaging for fragile items

When shipping multiple glass, porcelain, or electronic items in one master carton, the pad acts as a firm staging base. The tubular columns prevent individual items from shifting or striking the outer walls during transit.

Hazardous goods bracing

This pad is frequently specified for transporting regulated items, such as UN 3268 seatbelt pretensioners. The dense rolled columns keep dangerous goods strictly separated and immobilized within the outer shipper.

Lateral crush zones for heavy electronics

When delicate but heavy servers or power supplies need standoff distance from the box edge, the side tubes create a deep, multi-layered air gap that absorbs side impacts before they reach the central payload.

Industrial, Automotive, and Fragile Goods

Industrial and automotive parts

This pad secures dense, hazardous, or high-value industrial components. The four vertical walls created by the rolled tubes can support heavy top weight when stacked inside a master shipper.

Manual fulfillment operations

Because the unglued tubes spring back naturally, this insert requires manual assembly. It fits best in fulfillment centers where packers have the time and bench space to roll the columns and seat the pad into the outer box by hand.

Dangerous goods transport

Shippers moving regulated materials rely on the predictable crush resistance of the rolled tubes to meet strict separation and immobilization requirements during transit.

Lighter Payloads and Single-Wall Buffers

High-speed automated packing lines

The unfastened tubes will immediately spring open if not held closed. If your line relies on automated robotic insertion, a pre-glued partition or a self-locking tray is a safer choice.

Lightweight void fill

Rolling a 9-panel corrugated sheet consumes a massive amount of board. If you are simply taking up empty space around a light product, standard air pillows, crumpled paper, or a simple open C-channel will be far more economical.

Close variants and lookalike dielines

The closest library neighbors include 0942, 0941, 0945. Use this as a variant check if a buyer brings an old code, sample, or dieline that looks close. The deciding details are usually the lock, slot, closure, wall build, part count, or fold sequence.

Board Thickness, Blank Sprawl, and Packing Labor

Balancing board thickness with folding fatigue

Heavy double-wall board maximizes shock absorption but drastically increases the physical effort required to roll the tubes. If packers struggle against the board's spring-back tension, assembly slows down. Standard C-flute often provides the best balance of column strength and manageable folding.

Blank sprawl versus production simplicity

This pad can be produced on a standard slitter-scorer using only straight parallel creases. However, the flat blank is more than twice as wide as the finished pad. You trade complex cutting processes for higher per-unit material usage.

Master carton friction fit

This pad has no locking tabs or glue joints. It relies entirely on the side walls of the master carton to hold the rolled tubes closed. The pad must be dimensioned precisely to the internal width of the outer box to prevent the tubes from bowing or binding.

Packing line speed and manual handling

Because both side columns must be rolled and held against the board's spring-back tension simultaneously, packers generally need both hands free to seat the pad into the box before loading the product. This limits the speed of the packing line.

Channel Width, Tube Height, and Board Grade

Central channel width

The staging area between the two tubes can be widened or narrowed to match your exact product footprint. The side tubes will scale accordingly to fill the remaining space inside the master carton.

Tube height and clearance

The height of the side buffers dictates how much lateral crush zone you have. Taller tubes provide more standoff distance from the outer box walls but consume exponentially more corrugated board.

Board grade selection

While C-flute is common, the board grade can be adjusted based on the payload weight. Thicker boards require careful recalculation of the fold allowances so the inner panels do not bind when rolled.

Board and packing details

Subtractive fold allowances

To ensure the tubes close flat, the innermost panels must be slightly shorter than the top panels. This parametric nesting logic must be updated if the board thickness changes, otherwise the tubes will bow outward.

Additional notes

Two-handed packing requirement

Because both side columns must be rolled and held against the board's spring-back tension simultaneously, packers generally need both hands free to seat the pad into the box before loading the product.

Related Corrugated Inserts

0929: Open C-Channel

A simple 3-panel spacer that uses far less material but offers less crush resistance.

0945: Cushion Pad

Nearby FEFCO style to review if the buyer wants a similar job but the closure, flap overlap, wall build, or part count changes the package choice.

FAQs

Assembly and Packing

Does this pad stay folded on its own?

No. The corrugated board has natural memory and will spring open. A packer must hold both tubes closed while inserting the pad into the master carton, which then keeps the structure confined.

Production and Cost

Why does this pad use so much material?

To create the two closed tubes, the board must roll inward 360 degrees on both sides. This 9-panel sequence means the flat sheet is massive compared to the final folded footprint, driving up material usage.

Can this be manufactured with straight creases?

Yes. Because all the creases are straight and parallel, it can typically be produced on a standard slitter-scorer, avoiding complex cutting processes.

Product Fit

Is this a direct replacement for molded EPS foam?

It is a highly effective, fully fiber-based alternative for blocking and bracing heavy parts. However, because it relies on folded corrugated columns rather than molded contours, the exact shock absorption should be tested with your specific product and drop requirements.

Materials

Should we use double-wall board for maximum protection?

Double-wall board offers exceptional crush resistance, but it makes the pad very stiff and difficult to roll by hand. Standard C-flute is usually recommended to balance protection with reasonable packing labor.

Master Carton Fit

How tight should the pad fit inside the outer box?

It requires a precise slip-fit. If it is too loose, the tubes may unroll slightly and lose their structural strength. If it is too tight, the inner walls will bow outward and pinch the product in the central channel.

Assembly and Packing

How many hands are required to pack this?

Packers generally need both hands to roll the side columns and hold them against the board's spring-back tension while seating the pad into the box.

Does this work for automated insertion lines?

Generally no. The unfastened tubes will spring open immediately without specialized robotic end-effectors holding them closed until they are fully seated in the master carton.