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Acrylonitrile Butadiene Styrene (ABS) vs Polypropylene (PP) for Industrial Dunnage and Handling Trays: Which Sheet Wins in industrial equipment?

2026-10-02 Plastic News 0 views

Acrylonitrile Butadiene Styrene (ABS) and Polypropylene (PP) are the two most quoted sheet materials for industrial dunnage and handling trays in industrial equipment projects. Both run well on standard thermoforming equipment, but they differ in clarity, toughness and sealing.

The notes below come from day to day production and export work with overseas buyers.

Product Overview

This category covers a family of products rather than a single item. In practice a buyer defines industrial dunnage and handling trays by three things: the base resin, the format or dimension, and the performance or certification level it has to meet. Typical options in this category include custom cavity layouts; ESD and conductive grades; returnable and reusable designs. Materials most often specified are Polycarbonate, High Density Polyethylene, Polyethylene Terephthalate, Polypropylene, and the choice between them changes stiffness, temperature resistance, chemical behaviour and price.

In the industrial equipment sector the decision is usually driven by thick gauge capability and flare and fire rating, with paintability as a secondary requirement. Typical end uses include equipment covers, kiosk shells, twin sheet panels.

Key Material Properties

The table below summarises the values that usually decide the material choice.

MaterialDensityTensile strengthService temperature
Acrylonitrile Butadiene Styrene1.04-1.06 g/cm³30-50 MPa-20°C to 80°C
High Density Polyethylene0.94-0.97 g/cm³20-32 MPa-50°C to 80°C
Polyethylene Terephthalate1.35-1.40 g/cm³50-70 MPa-40°C to 70°C

Acrylonitrile Butadiene Styrene is frequently the default selection here: ABS is the default choice when a part needs a glossy, paintable, impact-resistant surface.

Acrylonitrile Butadiene Styrene Compared With Polypropylene

Acrylonitrile Butadiene Styrene grades offer high impact toughness, while Polypropylene brings lowest density among commodity plastics. For industrial equipment service the difference shows up in impact strength and in the long term behaviour under load.

  • Acrylonitrile Butadiene Styrene: ABS is the default choice when a part needs a glossy, paintable, impact-resistant surface.
  • Polypropylene: PP is the lightest mainstream packaging resin and keeps its shape under repeated flexing.

The practical decision usually comes down to the service environment: temperature, chemical exposure and expected lifetime.

Common Grades and Variants

  • Polycarbonate based: outstanding impact strength (250x glass)
  • Polyethylene Terephthalate based: excellent barrier to CO2 and moisture
  • High Density Polyethylene based: high impact strength even at low temperature
  • Polypropylene based: lowest density among commodity plastics

Beyond the base resin, most suppliers offer UV stabilised, food contact, flame retardant, anti-static and recycled content versions of the same product. Ask which additive package is included, because it is often the difference between a part that lasts three years and one that lasts ten.

Processing and Finishing Options

Processing method drives both cost and performance, so it should be fixed early in the design.

  • Welding
  • Assembly
  • Twin sheet forming
  • Cnc trimming

Secondary operations such as printing, welding, machining and assembly are often cheaper to do in the same factory, and they reduce the risk of mismatch between components.

How to Specify Industrial dunnage and handling trays Correctly

Work through these points in order and most specification mistakes disappear.

  1. check stack load and conveyor compatibility
  2. validate washing and drying resistance
  3. design locating features that survive repeated use
  4. define the number of returnable trips expected
  5. specify ESD grade if electronics are handled

Send this list to your supplier with the drawing and you will receive comparable quotations from every factory you contact.

Frequently Asked Questions

What tolerance can be achieved?

Standard production tolerance follows the relevant ISO or DIN tolerance class for the process; tighter tolerances are possible after machining or grinding, but they add cost. Define the tolerance only on the functional dimensions.

How do you control colour consistency?

Colour is controlled with a masterbatch reference approved by the customer, and every production lot is checked against the approved sample under standard lighting before shipment.

Can you produce industrial dunnage and handling trays in Acrylonitrile Butadiene Styrene?

Yes. {mat1} is one of our regular materials for this item, and we can supply virgin, modified and certified grades with full traceability. Material certificates and test reports are issued per batch.

Do you offer samples?

Yes. Standard samples are normally free of charge and shipped within three working days; custom samples are charged at cost and credited against the first production order.

What is the minimum order quantity for industrial dunnage and handling trays?

For standard sizes and colours the minimum is usually one pallet or one production run; for custom tooling the economic minimum depends on the tooling cost amortised over the expected volume. Send us your annual volume and we will calculate the break even point.

Conclusion

If you are planning a new industrial equipment project, send us your drawing, annual volume and target properties, and we will come back with a material proposal, a tooling plan and a budget quotation.

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