Smurfit Kappa develops paper-based alternative to plastic board pallet tops

Smurfit Kappa
Smurfit Kappa TOPPSafe

Paper producer Smurfit Kappa has invented a sustainable recyclable alternative for heavy wooden, chipboard, and plastic boards that are used to protect palletised products during transport and storage.  

A team of Smurfit Kappa designers in its Hexacomb operations worked together to find a food-safe and innovative solution that would be suitable for many sectors. 


Made from 100% paper-based material, the TOPPSafe is crafted from Hexacomb material which is lightweight and strong due to its structure. 

According to the company, its customers were struggling with the weight and inflexibility of the wooden, chipboard and plastic pallet tops that are currently used in supply chains which are often dropped leading to a risk of injury. 

TOPPSafe is lighter meaning it is easier to handle and is supplied flat to reduce storage space. The material used is also fully recyclable.  

Smurfit Kappa Hexacomb managing director Wim Peeters said: “We are very excited about launching TOPPSafe because it has the potential to have a transformative effect on the supply chain. The feedback from the customers who have been using it already has been unanimously positive. At Smurfit Kappa, we aim to come up with solutions that score highly when it comes to safety, sustainability and innovation.”

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