Welcome to the Dufaylite Blog, Dufaylite are the sole UK Manufacturer of recycled paper honeycomb, a strong and sustainable material with many industrial and creative applications.
Dufaylite has 6 divisions, consisting of Ultra Board, Clayboard, Fire Protection, Panels, Packaging and Honeycomb.
Ultra Board
Dufaylite Ultra Board is a range of lightweight paper honeycomb boards and can be used for various applications in the print and display market. Dufaylite distributes Ultra Board directly to the print and display market and offers additional services that most traditional distributors do not offer. Dufaylite can provide technical advice for fabrication of the board material but they can also help by offering a cut to size and shape service along with a covering and printing service.
The Ultra Board range consists of 5 different types that each offer unique benefits.
Ultra Board R is made from 100% recycled paper and is ideal for applying various facings and finishes.
Ultra Board GR is a double sided print susbtrate designed specifically for direct to media printers for signage, POP and displays.
Ultra Board MR has a moisture resistance, this is ideal for applications that involve waterbased adhesives.
Ultra Board FR has a class 1 fire rating, this is ideal when fire safety is the main concern.
Ultra Board CR is a coloured board that is matched to your specific pantone requirements.
Clayboard
Clayboard® is a unique, environmentally friendly void former and foundation stabiliser developed by Dufaylite for the construction industry. Clayboard® is a biodegradable honeycomb core set between lightweight polypropylene facings. Water is introduced to the Clayboard® core once the concrete slab or beam is set, degrading the Clayboard® honeycomb centre which leads to the creation of a void.
This space will accommodate clay expansion without exerting undue pressure on the structure above. The resulting void continues to accommodate natural soil shrinkage and expansion.
The damage risk posed by natural shrinkable clay soils is well known to engineers and builders. Changes in the soil water content cause shrinkage or expansion which, if not properly accommodated, can exert intolerable pressure on any building standing on the site causing structual damage.
Shrinkable clay soils are present all around the world. In the UK, these soils can be found deposited throughout the country and most commonly in the South East, falling in an area between Exeter and Hull. However climatic changes are now affecting similar soils in the North.
Apart from the immediate advantages of a slimmer product requiring shallower foundations and less soil extraction, Clayboard® has specific advantages over other methods of void creation.
Fire Protection
Dufaylite manufacture a complete range of fire protection systems, specifically designed to give building contractors flexibility and reliable protection from 30 minutes to 4 hours in a wide variety of applications.
Included in the Dufaylite range of fire protection products are fire dampers & grilles, firesleeves & pipe wraps, strips and sealants, fire batts, bags and mortar to provide an effective passive fire solution for all parts of the building envelope.
Panels
Dufaylite panels are a sandwich construction of paper honeycomb core bonded to outer facings both sides. Because of their cellular core, Dufaylite panels have an enormous strength to weight ratio, offering significant advantages over solid composites.
Widely used for exhibition stands, signs, retail, office, caravan and boat fixtures and fittings, Dufaylite panels are available in a complete range of constructions to suit virtually any application. A wide choice of standard outer facings gives total flexibility with the option of profiled shapes, edge lipping and angling. Their lightness means they can be used where weight and safety are important factors.
The choice of panel formats, thicknesses and finishes provides tremendous scope for creativity. And because manufacture is all under one roof, quality of panel construction is assured.
Dufaylite panels can be split into two varieties, As Pressed panels and Timber Framed panels.
Dufaylite as pressed panels are manufactured using a honeycomb core with various outer facings on both sides to order. This gives a lightweight and uniquely robust panel.
Dufaylite timber framed panels are manufactured from a timber framing with a honeycomb core with various facings on both sides to order. The timber frame can be groved for fabric tucking, extrusion fixing and panel joining.
Honeycomb
Dufaylite paper honeycomb packaging is a natural option for today’s environmentally conscious public. The combination of the product’s outstanding features combine to make it a leading contender for a wide variety of packaging applications across all industries.
100% recyled and 100% recyclable and highly cost effective, Dufaylite packaging has been designed to protect all types of goods from damage during storage and transit, without adding extra weight to the load.
Dufaylite honeycomb is extremely versatile, and therefore perfectly suited to customised packaging. Through die-cutting, slit scoring and compression techniques, we can create complex, strong and protective packaging to suit virtually any type of product.
Dufaylite’s unique honeycomb design has harnessed nature’s strongest natural structural form. The honeycomb’s compressive strength is not only strong enough to withstand impact and heavy loads, but is very lightweight with exceptional cushioning properties due to its inner cellular structure.
All Dufaylite packaging featured on this website are manufactured from recycled paper, attracting minimum recycling cost penalties in line with the Packaging Waste Regulations, and helping you keep packaging waste out of landfill.
Dufaylite honeycomb has an exceptional strength to weight ratio, making it an outstanding core material for all types of applications. The honeycomb is made from layers of paper or cardboard bonded together by parallel and uniformly spaced lines of adhesive. When it is expanded for use it forms a honeycomb configuration with hexagonal cells. It is environmentally-friendly, being manufactured from 100% recycled paper and the adhesives we use are water-based and bio-degradable.
The honeycomb sheets can be made in a range of thicknesses and honeycomb cell sizes to cater for a huge variety of applications.
Special coatings and facing boards can be applied to the basic honeycomb sheets to provide characteristics such as fire-resistance, rigidity or display-quality surfaces, and can be shaped, slit and cut.