At a Glance
- 1000kg/m²+ Compression Target
- 30% Less Drying Delay
- 0 Curl Failures in Pilot
Lower moisture introduction mattered because the core and liner both contributed to how the finished panel moved during drying.
Moisture-heavy lamination was creating curl, slower drying, and compression uncertainty
The converter was building structural honeycomb panels for flat, load-bearing applications, but the existing adhesive system introduced too much water into the board structure to keep geometry stable.
- Panels developed a visible banana effect after lamination and drying, which made them harder to use in doors, pallets, and other flat structural formats.
- The drying window stretched longer than the line wanted, turning panel stabilization into a bottleneck instead of a controlled handoff.
- Teams also needed better confidence that a flatter board would still keep the internal bond and compression performance the program required.
A lower-moisture lamination route tuned around lay-flat behavior, drying balance, and structural hold
Senda shifted the project away from a glue-only mindset and treated it as a moisture-management problem, balancing solids, wetting, and set behavior so the board could stay flatter without sacrificing panel strength.
Products Used:
- Lay-Flat Honeycomb Lamination System
Designed to reduce moisture carry, stabilize panel geometry, and support structural honeycomb bonding.
The useful insight in this program was that curl control and structural strength had to be qualified together. A flatter panel was only valuable if the liner-to-core bond still held through load expectations and downstream converting.
Qualification path
Panel build and moisture review
Paper basis weight, core structure, adhesive add-on, and drying conditions were reviewed together to identify where excess water was distorting the finished board.
Lay-flat and drying checks
Trial panels were compared for curl behavior, stabilization time, and whether the board held a flatter profile after drying instead of springing into a banana effect.
Structural performance confirmation
Compression performance remained part of approval so a flatter board did not come at the cost of weaker structural lamination or poor pallet and door-core confidence.
The target was not only adhesion between liner and core. The board had to stay flat enough for downstream structural use.
What changed on the honeycomb line
- More stable lay-flat performance: The approved adhesive route reduced the moisture-driven tendency for boards to curl after lamination and drying.
- Lower drying pressure: Panels moved through stabilization with less waiting and less process drag than the previous moisture-heavier setup.
- Stronger structural confidence: Compression expectations remained in scope, so the converter did not have to trade flatter boards for weaker finished performance.
Validated operating window
Validated operating window
Approval stayed tied to whether panels held a usable flat profile after lamination and drying.
Structural performance remained aligned with the heavy-duty compression expectation on the solution page.
The lower-moisture route shortened stabilization pressure versus the previous lamination setup.
Related resources
- Preventing Honeycomb Board Defects: Moisture, Spread Rate, and Pressure Settings
Anti-curling spread rate and lamination pressure—the guide for this honeycomb qualification.
- Request a honeycomb lamination trial
Prepaid sample for flatness and curl screening on your honeycomb paper and press settings.
" Senda's anti-curling adhesive solved our biggest quality issue. Our boards stayed flat, and we were able to move the lamination line faster with fewer drying bottlenecks. "
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