Interactive 3D

1 / 3

EVF92004

Circular Die-Cut Pad and Divider

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.

Get pricing

Free white-glove consultations. Blazing-fast response time. Fast quotes.

Product details

Top highlights

Flat circular profile for cylindrical packaging
Used for layer separation, base support, or top lining
Requires an outer container for shipping and handling

About this product

The EVF92004 is a flat, circular die-cut pad designed to drop into cylindrical containers, tubes, and round boxes. It functions as a simple layer divider, base stiffener, or protective lid liner.

Because it has no folds or structural walls, its performance depends entirely on the chosen board grade and an accurate diameter fit within the parent container.

Common uses

Layer dividers for stacked items in tubes
Base stiffeners for round food containers
Printed informational cards placed under a tube lid
Top dust covers for open cylinders

Get a quote

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

Describe your project *

Approximate quantity *

Size if known

Files or competing quote (optional)Drag files here or choose filesAdd drawings, photos, dielines, quotes, specs, or other useful files.Max 5 files, 25 MB total.

Name *

Email *

Phone

Optional

More details

You can skip this whole part, or open a section and answer only what you know.

Size and quantity

Detailed dimensions

Units US customary (inches)Metric

What do your dimensions describe?

Diameter

Size notes

Quantity notes

Materials and print

Paperboard preference

Add details for paperboard preference

Paperboard details

Print and artwork

Add details for print and artwork

Print, finish, or artwork details

Shipping or storage context

Custom changes or unusual needs

How will you use this circular pad?

Will the pad touch bare food?

Do you need any holes or edge notches cut into the pad?

Current box or specs

Do you have a current box, spec, or target sample?

Add details for do you have a current box, spec, or target sample?

Current box, known specs, or current problem

Destination ZIP or region

Company

Any deadline or timing constraint?

Layer separation and base support for cylindrical packaging

Layer separation in tubes

Drops into cylindrical packaging to separate stacked products, preventing scuffing and weight transfer between individual items.

Base reinforcement

Adds a rigid floor to round containers, distributing product weight more evenly across the bottom and reducing the risk of base sagging.

Printed lid liners

Acts as a branded insert or informational card placed at the top of a tube, providing a clean presentation surface immediately upon opening.

Top dust covers

Rests on top of the product inside an open cylinder or tin, providing a barrier against dust and debris before the main lid is applied.

Product categories using circular pads

Cosmetics and personal care

Often used inside rolled-edge paper tubes to separate stacked jars or provide a printed greeting card before the product is revealed.

Confectionery and specialty food

Serves as a base pad for cakes, cookies, or stacked treats when cut from appropriate grease-resistant or food-contact boards.

Industrial components

Acts as a spacer for cylindrical parts shipped in tubes, keeping metal or plastic surfaces from rubbing during transit.

When to compare rectangular or shaped pads

Square or rectangular parent containers

If the outer box has straight walls, a standard rectangular pad provides edge-to-edge coverage without leaving open gaps in the corners.

Oval or custom profiles

If the container is not perfectly round, an elliptical pad or a custom-traced profile prevents the insert from shifting laterally.

Need for vertical clearance

If the pad needs to sit above the base without resting directly on the product, a tray or platform with folded legs is required instead of a flat sheet.

Clearance, material, and print choices

Diameter clearance

The pad must be sized slightly smaller than the parent container's internal diameter. A tight fit can cause the board to bind or bow during insertion, especially with thicker corrugated grades.

Material stiffness

Corrugated board offers cushioning and rigidity for heavy items, while solid bleached board (SBB) or folding boxboard (FBB) provides a smooth, premium surface for printing and presentation.

Print and coating

If used as a presentation liner, decide if one or both sides require printing, and whether a protective coating is needed to resist moisture or product oils.

Direct food contact barriers

If the pad will sit directly under baked goods or confectionery, the board must be specified with an appropriate food-safe or grease-resistant barrier.

Cutouts and edge modifications

Center cutouts

A central hole can be added to help locate a specific product component or to give users an easy way to hook a finger and lift the pad out of the tube.

Edge notches

Small perimeter notches can be cut to bypass internal container seams or assist with manual extraction without bending the pad.

Flat edges for rotational alignment

If the pad features printed text that must stay upright, a small flat edge can be cut to key into a matching feature in the parent container, preventing the circle from spinning.

Packing details

Nesting and material yield

Circular shapes inherently leave matrix waste between blanks on a production sheet. This makes them slightly less material-efficient per square inch than rectangular pads that share straight cutting rules.

Automated placement

While simple to drop in by hand, these pads can also be handled by suction-cup robotic pick-and-place systems if the top surface is smooth and non-porous.

Additional notes

Rotational alignment for printed pads

If the pad features printed text or logos, consider that a perfect circle can rotate freely inside the tube. If orientation matters to the unboxing experience, a notched edge or a different container shape may be necessary.

Food contact suitability

If the pad will sit directly under baked goods or confectionery, the board must be specified with an appropriate food-safe or grease-resistant barrier.

FAQs

How much smaller should the pad be than the container?

The diameter usually needs a slight reduction compared to the container's internal width. This ensures it drops in easily without binding, which is especially important for thicker corrugated boards.

Can this pad be printed on both sides?

Yes, flat pads can be printed on one or both sides, making them highly useful as informational inserts, branding cards, or decorative lid liners.

Does this pad provide structural protection?

It provides puncture resistance and layer separation, but it relies entirely on the outer tube or container for overall crush resistance and containment.

Are circular pads more expensive to cut than square ones?

The cutting process is similar, but circles do not nest perfectly on a sheet. This leaves unavoidable matrix waste, which can affect overall material yield compared to straight-cut rectangles.

Can we add a hole in the middle?

Yes, a central cutout can be added to hold a specific component or to give users an easy way to lift the pad out of a tight tube.

Is it easy to test different diameters?

Yes, flat pads are very simple to prototype on a digital cutting table, allowing you to test the exact drop-in clearance with your physical container before committing to a production die.

How are these pads delivered to the packing line?

They are usually stripped and stacked flat. For some automated handling setups, they may be delivered lightly nicked in the sheet, but loose stacks are the most common format.

How do I keep a printed circular pad from rotating inside the tube?

A perfect circle will spin freely. If orientation matters for unboxing, adding a small flat edge or notch that keys into the parent container is necessary.

Will a thick corrugated pad bend when pushed into a tight tube?

Yes, if the clearance is too tight, the pad will bow or bind during insertion. Thicker boards require slightly more diameter reduction than thin paperboard to drop in smoothly.