The Manufacturing Process of PP Bubble Board: What You Need to Know

The Manufacturing Process of PP Bubble Board: What You Need to Know

Summary

Discover how Polyreflex manufactures high-quality PP Bubble Boards using advanced co-extrusion technology. Learn about the step-by-step production process, material structure, and quality control that make our polypropylene bubble sheets lightweight, durable, and eco-friendly.

The Manufacturing Process of PP Bubble Board: What You Need to Know
PP Bubble Board, also known as polypropylene bubble sheet, is a lightweight yet durable thermoplastic material that has gained wide popularity across various industries — from packaging and automotive to construction and display. Its distinctive internal bubble structure gives it excellent strength, rigidity, and cushioning properties, while keeping it remarkably light in weight.
At Polyreflex, we have over 18 years of manufacturing experience specializing in polypropylene sheet materials. In this article, we'll take you behind the scenes to explore the complete manufacturing process of PP Bubble Board, so you can better understand how this innovative material is made and what makes it so reliable.

What Is PP Bubble Board Made Of?

The main raw material used in PP Bubble Board is polypropylene (PP) resin — a versatile thermoplastic polymer known for its toughness, chemical resistance, and recyclability. To achieve specific performance characteristics, the PP resin is blended with several functional additives, such as:
  • Color masterbatch – to provide customized colors
  • UV stabilizers – to enhance outdoor weather resistance
  • Anti-static agents – for electronic packaging applications
  • Coupling agents or impact modifiers – to improve mechanical performance
    • Polyreflex uses 100% virgin polypropylene resin, ensuring that every sheet maintains stable physical properties, superior appearance, and consistent quality.

    The Structure of PP Bubble Board

    Unlike solid sheets, PP Bubble Board is built with a three-layer co-extruded structure:
  • Top surface layer
  • Middle bubble core layer
  • Bottom surface layer
    • The middle layer contains numerous sealed air bubbles arranged in a hexagonal or circular pattern. These air-filled bubbles provide cushioning and rigidity, similar to the concept of a honeycomb. This structure allows PP Bubble Board to achieve a perfect balance between strength, stiffness, and light weight.

    Step-by-Step Manufacturing Process

    1. Raw Material Preparation

    The process begins with the selection of high-purity PP resin pellets. These pellets are mixed with additives and color masterbatch according to the required formula. The mixture is then dried and prepared for extrusion.

    2. Co-extrusion

    The dried material is fed into a co-extrusion line equipped with multiple extruders. One extruder produces the top and bottom skin layers, Another extruder forms the bubble core layer. The materials are melted and combined in a multi-layer extrusion die, ensuring excellent adhesion between the layers. This co-extrusion process is the key to creating a uniform and durable PP Bubble Board with consistent thickness and density.

    3. Bubble Formation

    As the molten material passes through the specialized die, air pressure and temperature are precisely controlled to form sealed air pockets — the “bubbles.” The size and distribution of these bubbles directly affect the board's strength and weight. Polyreflex uses precision-designed forming molds to ensure a stable, evenly distributed bubble structure. This step gives the PP Bubble Board its unique internal architecture, combining flexibility with mechanical rigidity.

    4. Cooling and Calibration

    After the bubble structure is formed, the sheet passes through a cooling and calibration system that shapes it into the desired thickness and flattens the surface. Cooling rollers control the sheet temperature and prevent deformation. The calibration table ensures consistent thickness tolerance and smooth surface finish. This step is critical to achieving dimensional stability and surface uniformity in the final product.

    5. Surface Treatment (Corona or Lamination)

    Depending on the intended application, PP Bubble Board can undergo surface treatment to enhance its performance:
  • Corona treatment: improves surface tension for better printing and adhesive bonding, ideal for advertising or labeling applications.
  • Lamination: a protective film can be applied for scratch resistance, gloss, or matte finish.
    • At Polyreflex, our surface-treated PP Bubble Boards offer excellent printability and versatility, making them suitable for both industrial and commercial use.

    6. Cutting and Finishing

    Once the board cools and solidifies, it is trimmed and cut into standard or custom sizes.
    Polyreflex offers full customization, including:
  • Thickness range: 2mm – 29mm
  • Weight range: 300 – 4800gsm
  • Colors: white, black, gray, blue, and other customized options
    • Each batch is labeled and packed for shipment or further processing, such as die-cutting, bending, or welding.

    Quality Control and Testing

    Every PP Bubble Board produced by Polyreflex undergoes strict quality control at multiple stages of production. Key tests include:
  • Thickness and density measurement
  • Flatness inspection
  • Impact and compression strength testing
  • Surface appearance and color uniformity check
    • We maintain an ISO 9001-certified quality management system, ensuring consistent product performance that meets international standards.

    Customization Options

    To meet diverse industry demands, Polyreflex offers custom PP Bubble Boards with specialized functions:
  • Anti-static and conductive types – for electronic product packaging
  • UV-resistant types – for outdoor or automotive use
  • Flame-retardant types – for safety-critical environments
  • Printable and laminated surfaces – for display or signage
    • Our experienced engineering team can adjust the formulation, surface texture, and mechanical strength according to your specific requirements.

    Advantages of PP Bubble Board Manufactured by Polyreflex

    Choosing Polyreflex means choosing reliability and innovation.
    Our PP Bubble Boards stand out because of:
  • 18 years of manufacturing experience in thermoplastic sheet production
  • Advanced co-extrusion equipment ensuring precision and efficiency
  • Environmentally friendly materials — 100% recyclable polypropylene
  • Comprehensive quality control system from raw material to finished sheet
  • Global supply capability and fast delivery
    • Whether you need material for packaging, automotive lining, or reusable containers, Polyreflex delivers dependable performance every time.
    From raw material preparation to precise bubble formation, every step in the manufacturing process of PP Bubble Board contributes to its superior mechanical strength, lightweight design, and versatility.
    With advanced technology and years of expertise, Polyreflex ensures that each PP Bubble Board meets the highest quality standards.
    Contact Polyreflex today to learn more about our PP Bubble Board solutions or to request a quote for your next project.