Coroplast 101

Coroplast signs are a staple of affordable outdoor advertising – from real estate yard signs to political campaign placards. In this comprehensive guide, you’ll learn everything you need to know about coroplast signs, including what they’re made of, how they’re manufactured, and tips for starting your own business printing and selling these signs. We’ll also explore why coroplast signs are so popular (hint: they’re inexpensive, durable, and effective) and how you can leverage that popularity to grow a successful print business. Let’s dive in!

What Are Coroplast Signs?

Coroplast is actually a trade name for a specific type of corrugated plastic sign material. Essentially, a coroplast sign is made from a twin-wall plastic sheet with a fluted (hollow) core, very much like plastic “cardboard.” Most coroplast sheets are made from a high-impact polypropylene copolymer – a type of plastic known for being lightweight, waterproof, and tough. The fluted design (see image above) gives the material rigidity while keeping it extremely light in weight. This is why coroplast signs are easy to carry, mount, and move around, yet they hold up well in outdoor conditions.

Almost all standard corrugated yard signs – the kind you see for real estate listings, election campaigns, lawn services, etc. – are made of coroplast. The material’s smooth, printable surface and weather resistance make it ideal for temporary signage. In fact, Coroplast® sheets were formulated specifically for the sign and display market, designed to take printing (screen printing or digital) well and withstand the elements. They are waterproof, resistant to most oils and solvents, and can handle hot or cold weather without warping. Coroplast signs can last anywhere from a few months to a couple of years outdoors depending on conditions – plenty long for most short-term advertising needs.

Alternatives: While corrugated polypropylene dominates the yard sign market, there are other sign materials out there. PVC (polyvinyl chloride) sheets are another popular option, especially for indoor signs. PVC is a solid plastic sheet (not corrugated) that is more rigid and heavier than coroplast. It has a smooth, flat surface that allows very detailed printing and a professional look. However, PVC signs are generally better for indoor or short-term outdoor use, as they can warp in high heat and direct sunlight over time. On the higher end, acrylic (PMMA) and polycarbonate sheets are used for more permanent signage, like illuminated signs, office plaques, or long-term outdoor displays. These materials are much sturdier and more impact-resistant (polycarbonate, for example, is virtually unbreakable and great for backlit signs). Acrylic and polycarbonate signs have a glossy, professional appearance and excellent durability, but they cost significantly more than coroplast and are typically used when a high-end, long-lasting sign is needed (for instance, an outdoor business logo sign or an architectural sign on a building). In summary, coroplast signs fill the niche for affordable, lightweight, temporary signage, whereas PVC, acrylic, and polycarbonate serve other needs (from mid-range indoor signs to premium, long-term installations).

How Are Coroplast Signs Made?

Creating coroplast signs involves two main stages: manufacturing the corrugated plastic sheets, and then printing (or applying graphics to) those sheets to turn them into finished signs. Let’s explore both:

Manufacturing Corrugated Plastic Sheets (Polypropylene)

Coroplast (corrugated polypropylene) sheets are produced through a specialized plastic extrusion process. It starts with raw PP (polypropylene) pellets that are heated and melted down. The molten polypropylene is then plasticized and extruded through a die to form a flat, twin-wall sheet with the characteristic fluted core. The manufacturing equipment precisely controls the sheet’s thickness (common sign thicknesses range from about 2mm up to 10mm or more) and ensures the walls are flat and even. A secondary heating step often follows extrusion to anneal the plastic – this relieves stress in the material and prevents unwanted warping or deformation as the sheets cool.

The result is large panels of corrugated plastic, which are cut to standard sizes (often 4×8 foot sheets for supply) or custom sizes. Quality control is important at this stage: manufacturers perform checks to make sure each sheet is uniform in thickness and flatness, and that the flutes (the hollow channels) are consistent and give the sheet good rigidity. The base polypropylene material is typically naturally translucent or white, but colorants can be added to create sheets in many different colors. Additives can also be mixed into the plastic as needed – for example, UV inhibitors to improve sun resistance, or flame-retardant and anti-static additives for special applications. (Coroplast can even be made food-safe for agricultural boxes, or conductive for electronic packaging – showcasing its versatility.)

Once the raw corrugated plastic sheets are made, they are shipped out in bulk to printers and sign makers – or to wholesale distributors (like those PrintSprout works with) who can then custom-print them for end users.

Printing and Finishing Coroplast Signs

Turning a blank corrugated plastic sheet into a finished sign can be done in a couple of ways. For large production runs of simple signs (like one-color or two-color political yard signs), screen printing is a common method. Screen printing involves pushing ink through a stencil (screen) onto the plastic surface. It’s cost-effective for high quantities of the same design. For more complex full-color designs or smaller batches, digital inkjet printing is typically used – often with large flatbed UV printers that can print directly onto the coroplast sheet. UV-curable inks are ideal because they bond to the smooth plastic surface and are instantly cured by UV light, which prevents ink from smearing or flaking off. (Since polypropylene is non-porous, regular inks could rub off if not cured or treated properly. Corona treatment or an alcohol wipe of the surface is sometimes done to improve ink adhesion.)

If a print shop doesn’t have a flatbed printer, another approach is to print the design onto adhesive vinyl and then mount that vinyl onto the coroplast board. In practice, this means using a large-format printer to produce a sticker (often a laminated vinyl print for durability), and then carefully sticking that onto the corrugated plastic blank. This method works well for low-volume custom signs – essentially creating a decal that is applied to the coroplast. It’s “easy to do” even as a small business printer, as one sign-making tutorial notes, and yields vibrant, full-color results on coroplast. The vinyl adhesive approach also allows you to utilize standard roll printers if you don’t have specialized equipment to print directly on rigid boards.

After printing, the coroplast sheets are typically cut down to the desired final size (unless they were pre-cut). Common yard sign sizes are 18”x24”, 12”x18”, 24”x36”, etc., but you can make custom dimensions as needed. The flutes (corrugations) in the sign can be oriented vertically or horizontally depending on how the sign will be mounted. For example, yard signs that use H-wire stakes need vertical flutes (so the metal stake prongs can slide up into the hollow channels of the sign). Other finishing options include adding grommets (for hanging a sign), or even laminating the surface with a clear UV protective film if extra longevity is required. Many wholesale sign printers offer options like UV coating or lamination to help coroplast signs last longer under direct sunlight and harsh weather – a useful add-on since standard coroplast by itself will eventually fade or become brittle after long sun exposure. With UV-protective coatings, these signs can endure outdoor conditions for a longer period before showing wear.

In summary, producing the finished product involves printing your artwork onto the corrugated plastic and then cutting/finishing as needed. Thanks to modern printing tech, you can get high-resolution, full-color graphics on coroplast that look fantastic – all while keeping costs low. This combination of low cost, ease of production, and decent durability is why coroplast signs are everywhere in the advertising world.

Key Characteristics and Benefits of Coroplast Signs

Coroplast signs have become incredibly popular for a reason. They offer a mix of features that hit a sweet spot for businesses and advertisers:

• Lightweight, Yet Durable: Coroplast signs are very light (being mostly air in that fluted core), which makes them easy to transport, install, or even mail to clients. Yet, the corrugated polypropylene is tough and impact-resistant, so it won’t shatter and can handle falls or bumps. The material is also waterproof and doesn’t rust or decompose. This durability-to-weight ratio is a major advantage over something like solid metal or wood signs for temporary uses.
  
• Weather-Resistant: Polypropylene plastic holds up well in rain and moisture – it’s essentially plastic, so it’s 100% waterproof. Coroplast also tolerates hot and cold temperatures. It won’t be damaged by sun or snow in the short term, though prolonged UV exposure over years can eventually cause some fading or embrittlement (as with most plastics). For campaigns or events lasting weeks or months, coroplast handles weather just fine. If needed, UV-inhibiting additives or coatings can be used to improve sun-resistance.
  
• Easy to Print and Customize: Coroplast’s smooth surface takes both screen printing and digital printing well (especially when properly treated or using UV inks). It also comes in a variety of base colors. Signs can be printed single-sided or double-sided. The standard 4mm (approx 3/16”) thickness fits the common H-stakes for lawn signs, but other thicknesses (e.g., 6mm, 10mm) are available for larger signs or added stiffness. Overall, it’s a very versatile medium – you can cut it, score and fold it (to make things like boxes or 3D displays), punch holes for hanging, etc. It even accepts Velcro or other fasteners if creating a modular display.
  
• Inexpensive: Perhaps the biggest draw of coroplast signs is their low cost. They are one of the most affordable signage options on the market for the size. Because the material is cheap and printing can be done quickly (even in large volumes), you can produce yard signs for only a few dollars apiece (depending on quantity and size). This makes them ideal for promotions, events, and small business advertising, where budget is a concern. Even a small business can invest in dozens of coroplast signs without breaking the bank. When comparing cost vs. durability, coroplast offers a lot of bang for the buck: it’s cheaper than solid plastic or metal signage, yet it can be used outdoors and reused multiple times. In fact, coroplast signs are reusable and recyclable – they can often be stored and used for recurring events (e.g., annual yard sales or seasonal promotions), and when you’re done, the polypropylene is 100% recyclable.
  
• Recyclable and Eco-Friendly: Polypropylene is a thermoplastic that can be recycled. Many coroplast signs find a second life through recycling programs (the material can be melted down and reformed). According to one manufacturer, PP corrugated board can be recycled and re-used many more times than traditional paper cardboard. Additionally, using coroplast can reduce waste compared to single-use paper signs, since the plastic signs last longer and don’t get ruined by rain. For environmentally conscious clients, you can highlight that coroplast is non-toxic, PVC-free, and can be recycled into new plastic products.
  
• Shock-Absorbent and Safe: Because of the hollow structure, coroplast has a bit of flex and shock absorption. It’s not brittle, so it won’t easily crack into sharp pieces. This can be important for safety – for example, large coroplast signs at events won’t splinter if the wind knocks them over. The edges of a coroplast sign aren’t sharp (unlike some metal signs), making them a safe choice for busy public areas or event signage where people might be nearby.
  

Common Uses: Given these properties, it’s no surprise that coroplast signs are used across many industries. Some of the most frequent applications include: real estate yard signs, political and campaign signs, event signage (fairs, festivals, church events, charity drives), construction site signs (e.g. safety notices or “Coming Soon” project boards), lawn care and contractor signs (those small signs left on a lawn by a landscaper or roofer advertising their work), and retail advertising (such as for sidewalk sales or new store openings). You’ve also likely seen coroplast used for “big check” props at fundraising events or raffle winnings – those oversized checks are often just custom-printed coroplast boards. Another fun use is for personalized party or wedding signs, since they can be printed in full color and are sturdy enough to display outdoors at a gathering.

Nonprofits and community organizations also love coroplast signs because they can get their message out inexpensively. A marathon or charity walk, for instance, might have dozens of coroplast route signs, sponsor signs, and participant greeting signs. Businesses appreciate that coroplast signs effectively act as 24/7 advertising – a lawn sign in front of a store or along a road is constantly visible to passersby, essentially a mini billboard at a fraction of the cost. In fact, quality signage that is easy to read can directly boost sales – research shows it can increase sales by up to 15% for a business. And one study found that stores with good, visible signs enjoyed significantly higher profits than those without. Statistics like those are great selling points when you propose a signage solution to a client: a simple coroplast sign can attract new customers and pay for itself many times over in increased business.

Overall, coroplast signs hit the sweet spot for effective advertising: they’re large and eye-catching, durable enough for outdoors, but affordable enough that even small businesses or campaigns can deploy lots of them. Now that we’ve covered the “what” and “why,” let’s move on to how you can capitalize on this popular product in your own business.

Starting Your Own Coroplast Sign Printing Business

If the idea of printing and selling coroplast signs sounds appealing, that’s because it is! There’s a strong demand for these signs across real estate, local businesses, events, and more – and someone has to supply that demand. In fact, the printing industry data shows that while some traditional print sectors (like paper offset printing) have slowed, large-format printing (including signage) is on the rise. The global large-format printer market (which covers things like sign printing) is projected to grow to nearly $10 billion in 2024, so there’s plenty of opportunity out there. Starting a coroplast sign business means you’ll be riding that wave of growing demand for affordable, effective printed signs.

That said, how do you actually get started? Here are some key steps and tips:

1. Partner with the Right Suppliers (PrintSprout Can Help)

One of the first things you need is a reliable way to get coroplast signs printed and delivered to your clients. You could invest in your own large-format printing equipment, but that requires significant capital and expertise. A more accessible route for many entrepreneurs is to partner with wholesale trade printers or manufacturers. PrintSprout, for example, is a platform that connects you to a network of wholesale print suppliers (including those who produce coroplast signs). Through PrintSprout, you can order custom-printed coroplast signs at wholesale rates and have them shipped directly to you or your client. This means you don’t need to own a printing press or keep stacks of plastic in your garage – you can leverage the platform’s suppliers. It’s essentially print-on-demand for signage, under your own branding.

Coroplast sign manufacturers and wholesalers exist all around the world – in the U.S., Canada, Mexico, China, etc. – and many of them are capable of producing high-quality prints on coroplast quickly and cheaply. The “magic,” of course, is finding a supplier that is cost-effective, delivers good quality, and can fulfill orders in your target area. PrintSprout simplifies this by vetting suppliers and showing you options. For instance, if your client is in California, you can source from a West Coast supplier to reduce shipping time and cost. If your client needs a specific feature (like a certain thickness or a rush turnaround), you can select a supplier that meets those needs. By tapping into a network of multiple coroplast printers, you also protect yourself from capacity issues – if one is busy, another can take the job.

PrintSprout isn’t just about sourcing print; it also provides tools to integrate these products into your own website or storefront. You can set up an online shop offering coroplast signs (and other print products), and when an order comes in, it’s fulfilled through the platform’s back-end by a wholesale producer. Your customer sees your branding and website, but you don’t have to manually handle production. This kind of arrangement is often called a print reseller or white-label printing model, and it’s a great way to start a business with minimal overhead. You focus on marketing and sales, while the production and logistics are handled by your print partners.

2. Build Your Website and Portfolio

Speaking of a website – you’ll want an online presence where you showcase coroplast sign products, allow clients to request quotes or place orders, and share information about your services. With PrintSprout or similar services, you might even get a ready-made web storefront to customize. Make sure your site highlights the benefits of coroplast signs (many of which we discussed earlier). Use engaging images of coroplast signs in action: for example, a photo of a vibrant “For Sale” real estate sign in a lawn, or a set of campaign signs peppering a roadside. Visuals help potential customers imagine their own sign on display.

It’s also helpful to include some use-case ideas on your site to inspire customers. Not everyone realizes they need a sign until you propose it. For instance, a small retail shop owner might not think about ordering a custom sidewalk sign – you can plant the idea by showing “Seasonal Promotional Signs” as a category, with an explanation that an eye-catching sign outside can increase foot traffic. In fact, you might mention that an updated outdoor sign can increase sales by 10–15% on average (backing it up with a credible stat, as we have). This positions you not just as a printer but as a marketing helper who understands the client’s business goals.

Don’t overload the site with too many different products at first; coroplast signs themselves can be your hero product. You can always expand later, but being the “go-to” coroplast sign provider in your area or niche is a good way to differentiate yourself.

3. Market to Key Industries and Niches

Identify who your target customers are likely to be. From our earlier rundown, you know that real estate agents, local service businesses, event planners, political campaigners, and nonprofits are heavy users of coroplast signs. A smart strategy is to approach these groups with tailored marketing.

For example, real estate agents: Every active realtor needs a stack of yard signs (for sale signs, open house signs, etc.) and they often reorder them as they wear out or when they get new listings. You could create a special offer for realtors, such as, “Order 20 coroplast yard signs, get 2 free” – appealing to their volume needs. Emphasize durability (signs that last through the seasons) and perhaps offer to include riders or accessories. Realtors also value consistency and service; if you can become their reliable supplier, they’ll stick with you. (Fun fact: A National Association of REALTORS® report noted that around 60% of home sellers use yard signs as part of their marketing strategy, so agents definitely need signs regularly.)

Local small businesses (retail shops, restaurants, contractors, etc.) are another segment. A clever, low-cost way to reach them is by using postcards or flyers to advertise your sign services – essentially using print to sell print. For instance, design a catchy postcard that shows before-and-after scenarios of a business with no sign vs. a business with a bright coroplast sign out front, along with a message like “Grab Customers’ Attention – Affordable Custom Signs Can Increase Your Sales!” Include that stat about 15% sales lift from good signage, and a limited-time discount offer for first-time orders. You can drop these postcards off in person as you visit local stores or mail them out to business addresses in your area. When walking around your town, keep an eye out for stores or offices with missing or old signage; those are prime leads. Don’t be shy about introducing yourself and leaving a card. You’re not just selling a piece of plastic – you’re offering them a way to boost their visibility and revenue.

Nonprofits and event organizers can be approached with creative ideas. Many nonprofits hold annual events (fundraisers, charity runs, community gatherings) and could use signs for direction, sponsor recognition, or publicity. One idea is to pitch them on those oversized presentation checks for donation ceremonies. For example, you might say, “Have you considered printing a giant check for when you present donations? It’s great for PR photos!” A lot of charities love that idea once it’s presented, and you can supply the coroplast “big check” with custom printing. Similarly, for events like festivals or fairs, suggest signage for entrances, booth labels, or photo backdrops. Because nonprofits are often budget-conscious, underscore coroplast’s cost-effectiveness and maybe offer a small nonprofit discount to build goodwill (they could become repeat clients and refer others).

Another tactic is to leverage seasonal opportunities. As mentioned in the content, you can create a marketing calendar for your existing customers. Let’s say you landed a few local businesses who printed coroplast signs for a summer promotion. Don’t let the relationship go cold – as autumn approaches, send them a friendly note: “Fall is coming! How about a fresh sign for your fall specials? Pumpkin spice season, back-to-school sales – a new coroplast sign can draw in the crowds. We’re offering 10% off fall-themed signs for orders placed this month.” This kind of proactive outreach positions you as a partner in their business, not just a one-time vendor. It can spark ideas in the client’s mind (“You know, a fall sale sign would be nice…”) and generate repeat business. The same can be done for other seasons or events (new year, holiday sales, etc.).

In doing all this, you transform from simply a seller of coroplast signs into a consultant who helps businesses grow using signage. That added value is what will set you apart from a generic online printer. Anyone can take an order; you’re providing ideas, strategy, and personalized service.

4. Provide Incentives and Superior Service

The print industry is competitive, but there’s plenty of room to stand out through customer service and smart incentives. Here are a few ideas:

• Volume Discounts and Loyalty: As mentioned, realtors or any client that orders regularly should feel rewarded for loyalty. You could implement a tiered pricing or a loyalty program (e.g., every 5th order gets a 5% discount, or orders above $X get free shipping). A realtor who sells 50 homes a year might need dozens of signs – securing their yearly sign business with a contract or discount can be very lucrative for you.
  
• Package Deals: Offer packages like “Starter Business Kit” – which might include a set of coroplast signs, plus maybe some postcards or banners – to new businesses. When someone is opening a new storefront, they often need a whole suite of printed materials. If you can bundle products, you increase your share of their print spend. However, even just within coroplast signs, you could bundle design services (“Free basic design layout with each sign order”) if you have graphic design ability, or bundle sign accessories (like including an H-stake and grommets with each yard sign by default).
  
• Fast Turnaround and Reliability: Many people order coroplast signs when they’re up against a deadline (an event date, an open house, etc.). Being known as the provider who can get signs delivered on time is huge. Leverage your supplier network to offer rush production if needed. If your supplier network (via PrintSprout or others) has facilities across regions, use that to ensure quick shipping. Make sure to buffer in a little time and always communicate clearly with clients about delivery times. Meeting a tight deadline with a smile will win you repeat customers and referrals.
  
• Show Success Stories: When you have happy clients, ask for testimonials or photos of the signs in action. Then, with permission, feature those on your website or social media. For example: a photo of a happy realtor next to a “Sold” house with your printed “For Sale” sign in front, captioned “Agent Jane Doe sold 5 homes this month using our coroplast signs to attract buyers!” These stories add credibility. They also inspire other potential clients (“If it worked for them, maybe I should try signs too!”).
  

Remember, the print market isn’t slowing down – it’s evolving. Traditional print shops are diversifying into signage, and local businesses continue to need tangible marketing like signs to complement digital efforts. By starting a coroplast sign business now, especially with a platform like PrintSprout backing you, you position yourself at the intersection of this stable demand and modern, efficient supply. With large-format printing seeing significant growth and innovations (automation, personalization, etc.), you’ll be in a good industry that’s moving forward.

Next Steps

Coroplast signs are a fun and profitable product to work with – they’re creative, impactful for customers, and relatively simple to produce with the right partners. You’ve now learned what coroplast signs are made of (corrugated polypropylene that’s lightweight, weather-resistant, and inexpensive), how they’re manufactured, and how they can be printed and finished. We also covered strategies for launching your own coroplast sign business, from leveraging PrintSprout’s supplier network to marketing tips for reaching key clients like realtors, local businesses, and nonprofits. The key takeaway is that coroplast signs can be more than just a product you sell – they can be a vehicle for you to deliver marketing value to businesses, helping them increase visibility and sales, which in turn drives your success as well.

If you’re excited to dive deeper, our journey isn’t over. In our next installment, we’ll focus specifically on advanced techniques to boost your coroplast sign sales and even how to automate parts of your business so you can scale up (yes, making that six-figure revenue is within reach!). We’ll discuss effective online marketing for print, tools to streamline order processing, and more real-world tactics to grow your sign business. Stay tuned for the next blog – “How to Sell Coroplast Signs: Tips to Skyrocket Your Printing Business”, where we’ll show you how to take everything you learned here to the next level. Happy printing!