The content on this page provides details relating to the carbon study for Dufaylite Honeycomb Board carried out by CarbonQuota in June 2025*.
*Disclaimer: Carbon footprints independently calculated and verified by CarbonQuota. Assessments cover cradle-to-grave greenhouse gas emissions of the product from materials, production, distribution and end-of-life waste. It is considered there is zero energy consumed using the product. For more information including assumptions made, please refer to the Frequently Asked Questions.
Overview
Company name: Dufaylite Developments Ltd
Product: Paper Honeycomb Board:
Date: June 2025
Project Number: DUF01_003
Goal: Internal decision-making and external communication.
Functional Unit: An insulating packaging solution (excluding thermal performance).
Boundary: Cradle-to-grave
Allocation procedures: Follows the ISO 14040/44 hierarchy for allocation, with mass-based allocation applied to shared inputs at the facility level, and the cut-off (recycled content) approach used for end-of-life.
Cut-off criteria: Mass & Energy inputs >1% were included. No more than 5% were excluded. Inputs with potentially high environmental impact – such as glues or inks – were included regardless of mass or energy contribution.
Data sources: Primary data from Dufaylite + secondary data
Time-related coverage: Data collection occurred during February – March 2025, reflecting typical full calendar year operations.
Geographical coverage: Dufaylite’s UK based manufacturing
Sensitivity Analysis: A targeted sensitivity analysis was performed to assess the robustness of results to key modelling assumptions and data variability.
Limitations and caveats: This study is a streamlined life cycle assessment (LCA) that follows the methodological principles of ISO 14040 and 14044. It focuses exclusively on the climate change impact category (i.e. carbon footprint) and does not include other environmental impacts such as water use, resource depletion, or toxicity.
Green Claims support
Claim: Dufaylite’s honeycomb board liners resulted in a 35-60% lower carbon footprint across the entire lifecycle compared to a lamb’s wool insulation alternative
Low-end comparison: H4 vs W1 (38.1%)
High-end comparison: H1 vs W1 (61.9%)
Conservatively rounded down to the nearest 5.
Claim: Dufaylite’s honeycomb board liner resulted in a 50-70% lower carbon footprint across its entire lifecycle compared to an expanded polystyrene insulation alternative.
Low-end comparison: H4 vs P1 (53.6%)
High-end comparison: H1 vs P1 (71.4%)
Conservatively rounded down to the nearest 5.
Why do we give a range such as 35-70%?
This is a truthful range based on what we studied, and is conservatively rounded at either end. It makes it clear Dufaylite are not trying to hide relevant information and it can be substantiated in a range of scenarios.
Results
A sensitivity analysis was conducted to assess how key modelling assumptions affect the cradle-to-grave carbon footprint per insulated box.
The following variables were adjusted:
- Data source for Honeycomb Board, comparing results using site-specific inputs versus a fully generic secondary dataset.
- Box design for the Honeycomb Board scenario: one using the topper with a double layer of double-walled corrugated wrap, and the other using the topper alone, without additional corrugated wrap.
- Alternative design, modelling a configuration where Honeycomb Board lines all 6 internal sides of the box, removing the need for any additional corrugated wrap.
- Material density for wool and EPS, to reflect variability in commercially available packaging grades.
Frequently Asked Questions
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How do Dufaylite’s paper honeycomb board liners compare to other insulation materials?
In a 2025 study, Dufaylite’s paper honeycomb board liners resulted in a lower carbon footprint of 35-70% across the entire lifecycle compared to lamb’s wool and expanded polystyrene insulation alternatives. Discover more here.
How do Dufaylite’s paper honeycomb board liners compare to lamb’s wool as an insulation material?
In a 2025 study, Dufaylite’s paper honeycomb board liners resulted in a 35-60% lower carbon footprint across the entire lifecycle compared to a lamb’s wool insulation alternative.
How do Dufaylite’s paper honeycomb board liners compare to expanded polystyrene as an insulation material?
In a 2025 study, Dufaylite’s paper honeycomb board liners resulted in a 50-70% lower carbon footprint across the entire lifecycle compared to an expanded polystyrene insulation alternative. Discover more here
What is a product carbon footprint, and why is it important?
The manufacturing process for most products requires energy-intensive processes, which traditionally rely on burning fossil fuels such as oil, gas and coal. This releases greenhouse gases into the atmosphere which trap more heat than normal in the atmosphere, which accelerates global climate change. Understanding and reducing a product’s carbon footprint means you can then do something about climate change.
Is this carbon footprint cradle-to-grave?
Yes, and it includes all raw materials, production, transport to warehouses, distribution to the end customer or consumer, and disposal at end-of-life. The study considered there is zero energy consumed in using the product by the end user or consumer due to the nature of the product.
Can Dufaylite tell me the carbon footprint of what it produces?
Yes, we can provide a carbon footprint for every job we produce for you. This is provided in kg CO2e and is certified by CarbonQuota.
What is CO2e?
CO2e is the standard measure for carbon footprints. It includes carbon dioxide as well as the other most important greenhouse gases created by human activities that contribute to climate change. These are converted to a much simpler to understand ‘carbon dioxide equivalent’, or CO2e.
What is the biggest factor in the carbon footprint of Dufaylie products?
The substrate itself like paper or plastic is usually the dominant contributor to a carbon footprint, accounting on average for approximately 50% of its impact.
How can I reduce my carbon footprint?
There are many ways you can make significant reductions to your carbon footprints. These include investigating a range of specifications, materials, and manufacturing processes, reducing transport distances, and enabling the end user to recycle the item. If the product requires energy while it is used it is important to ensure it is powered by renewable electricity.
What is Dufaylite doing about its carbon footprint?
We are aiming to reduce our use of fossil fuels in the manufacturing process, minimise waste, reduce transport, as well as investigate alternative materials produced by lower-carbon providers. We are carefully checking that any sustainability claims we make are backed up by science.
What sources do you use to come up with this carbon footprint value?
Product carbon footprints from CarbonQuota are calculated by accessing the widest possible range of databases and studies from across the world, which is being constantly updated and refreshed as new information becomes available. This combines sector specialist data, paid for data, publicly available data, opensource data, and CarbonQuota’s expertise.
How accurate is this carbon footprint, and what assumptions have you made?
Dufaylite has provided CarbonQuota with as much primary data about its activities as possible to improve the accuracy. In line with international standards, CarbonQuota’s experts make assumptions and use secondary data where information is not available.
How do I know I can trust this value?
Carbon footprints are independently calculated and verified by CarbonQuota, and externally assured against relevant international standards. As specialists in the environmental impact of packaging and print, CarbonQuota has developed a unique database. CarbonQuota uses industry standard tools as well as its own algorithm for the calculations.
Are Dufaylite’s paper honeycomb board liners sustainable/eco-friendly/green/better for the planet?
When people ask us about these phrases, our answer is that we have an independently verified study showing that Dufaylite’s paper honeycomb board liners resulted in a lower carbon footprint of 35-70% across the entire lifecycle compared to lamb’s wool and expanded polystyrene insulation alternatives.
Should I put the Dufaylite paper honeycomb board liners into my compost or let them biodegrade when I have finished with them?
Please keep these in use after you have finished with them by recycling them so other products can re-use the fibres.
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