Ensuring that a package arrives with its contents intact is critical for retailers and manufacturers of all types. This is especially true in the transportation industry, where fragile parts like glass must be moved between facilities for assembly. Medical and food suppliers also need antimicrobial and temperature control solutions.
A versatile solution in many of these cases is foam packaging. Foam comes in various customizable materials and is often more durable and lighter than bubble wrap or paperboard filler.
However, options abound in the world of foam packaging materials, and it can take several rounds of trial and error for a manufacturer to determine the correct type of foam for the specific application. This post looks at the most common foam packaging options and applications and how Adherex can help you select and implement the best solution for your needs.
Common foam packaging materials
Polyethylene Foam (PE) – PE is lightweight, durable, resilient, and has excellent dampening and insulation qualities. It is highly versatile and can be formed into a variety of molds, rolls, or sheets, making it a popular choice for general applications.
Cross-Linked Polyethylene Foam (XLPE) – Cross-linked PE foam has a smoother texture than standard polyethylene, which makes it ideal for protecting glass or other sensitive components or products. XLPE can be cut into densities, thicknesses, or chemical compositions to suit your specific needs best. Additionally, XLPE holds up well in high-temperature uses and bonds well with pressure-sensitive adhesives.
Expanded Polyethylene Foam (EPE) – EPE is highly resilient and applicable in several reusable scenarios, especially for fragile components.
Specialty Foams – There are a number of foams chemically formulated for specific applications, including:
- Neoprene blended – Highly flexible substance perfect for gaskets and other industrial uses.
- Urethane – Primarily used for temperature control insulation and general packing material.
- Poron – A highly resilient urethane foam used in a variety of applications.
- EDPM – Ideal for automotive seals and outdoor usage.
- PVC – Durable foam for construction and transportation applications.
- EPS – Anti-static foam ideal for electronics, retail, and general dunnage.
Learn more: Foams and Converting Infosheet
The benefits of foam packaging
- Highly versatile – Foam can be cut or formed into custom shapes molded to specific products or rolled, sheeted, or built out into any number of shapes, including peanuts, pearls, tubes, and cubes.
- Cost-efficient – Foam is lighter than most other packaging materials and reduces shipping costs.
- Dampens vibrations – Vibration can ruin any sensitive products or equipment, and foam is an effective means of protection.
- Resistant – Foam is generally waterproof, chemical resistant, and antimicrobial.
Choosing the proper foam for your application
Foam packaging materials come at several price points with no “one-size-fits-all” option. When making your decision, think through the following factors:
- Fragility – How fragile is your product, and how far must it travel? Delicate products such as glass need shock-absorbing foam, such as PE, to prevent breakage.
- Weight – Heavier items need additional support from durable foams such as urethane-based foam, while light items may need less dense foam or different shapes like sheets, rolls, or custom interleavings.
- Budget – Pricing for foam varies according to size, density, durability, and chemical composition. Often, manufacturers can find a more affordable foam solution simply by switching materials while still meeting the needs of their custom application. Working with an Adherex expert is one easy way to determine the most suitable material for your specific application and price point.
- Reusability – In some manufacturing applications, durable foam and shipping crates or totes will last many years. However, the longer foam lasts, the more expensive it tends to be.
Also read: Announcing the Adherex Stocking Program for Packaging Materials
Optimizing foam performance for varied applications
Foam is highly versatile, with numerous options to help you meet the specifications of your application and budget constraints. In fact, there are an overwhelming number of options. Our customers often have a clear idea of what they need and how much they are willing to spend but often need to figure out which foam best fits their application.
Our experts can help you select the suitable foam type, density, and shape to support your specific packaging needs and fit within your budget. Leveraging our comprehensive expertise spanning various markets, we’ve built a team of specialists focused on ensuring outstanding packaging performance during transportation and warehouse operations and in various final application scenarios.
Adherex also supports your team with design and development resources. We provide genuinely customizable foam with our 5-axis waterjet cutter, which is faster than die-cutting, is especially useful for rapid prototyping, and yields more material.
Get in touch to learn more about a custom foam application.
