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Flat out gives you more, with less.

With the introduction of our new FlatStack Ultralight® grade, we now produce sheets in the caliper range of 10 to 50pt. Our wide range in caliper offering, coupled with in-house design and testing capabilities, enables us to create custom solutions to meet your unique manufacturing requirements. This is especially important if you use automated equipment, because we can offer a custom sheet tailored to your specific product and production process -- saving you time and money.

Read more about FlatStack Ultralight, our lightweight value offering.

FlatStack original tier sheets

Made from 100% recycled fibers and completely recyclable, FlatStack paperboard sheets are a cost-effective solution that protects products on pallets during shipping, storage and retail display.

Compared to typical corrugated tier sheets, FlatStack sheets offer a minimum 5% reduction in weight and generally garner a minimum of 15% cost savings across the supply chain.

They also offer 5 times the amount of sheets per unit storage, and more than twice as many sheets shipped per truckload:

Sheets per Pallet
Pallets per Truckload
Sheets per Truckload
Corrugate C-Flute 150pt
56 17,920
FlatStack 24pt
21 42,000
FlatStack 30pt

Assuming 40"W x 48"L x 48"H

  • Calipers: 12-50pt
  • Design flexibility: square, round or custom corners and/or sizes
  • Custom die-cut designs available
  • Made with 100% recycled fiber
  • Minimum 85% post-consumer fibers
  • Acceptable in commercial OCC recycling programs
  • FSC certification is available (see below)
Sonoco is committed to responsible use of natural resources through responsible sourcing, recycling and use of recycled fiber in our paper-based packaging.  Sonoco’s U.S., Canadian, U.K., Brazilian and one of our Mexican mills are certified to one or more fiber certification programs.  These are:  the Forest Stewardship Council® (FSC®), Sustainable Forestry Initiative® (SFI®) and the Program for the Endorsement of Forest Certification® (PEFC®) Chain of Custody and Due Diligence System Standards.  Additionally, we have plants in our composite can packaging, industrial tubes & cores, and primary packaging carton operations that are certified to these programs and can produce certified packaging.  Overall sales (certified and not) by these mills and fiber certified plants is equal to 15% of Sonoco’s revenue.
All but three of our 19 global paperboard mills use 100% recycled fiber in their production.  Some amount of responsibly-sourced virgin fiber is needed for select grades of paperboard.  The amount of recycled fiber in our composite cans range from 60 to 80+ percent, depending on the product specifications for the package.  On average, the amount of recycled fiber used in our industrial tubes and cores exceeds 95 percent.

See the difference

One pallet of FlatStack tier sheets yields 266 pallet cubes; one pallet of corrugated tier sheets yields only 53 pallet cubes.

Markets served

FlatStack is used by industry giants in many markets, including:

And much more - anything put on a skid in a bag, bottle or can will benefit from FlatStack!

Download our FlatStack flyer

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Contact us

To learn what Sonoco can do for your business, please fill out our contact form

Or, call us at 888-499-5330.