Sensitive or expensive products come out from production shaped very diversely. They present corners, cutouts or buttons. Such features make them difficult to fit into the packaging of the same type. Through grooves and curves, our foam packaging accommodates those irregularities. The carved material adequately protects the products on all necessary sides.
Even if the items are not very expensive, they can become costly if damaged. Our custom-made foam packaging, used right from the beginning, ensures the products reach their destination safely. No matter the travel distance, the goods remain in place and protected.
We create functional and aesthetic foam packaging which blocks and braces individual products. These solutions solve complex packaging problems. They precisely fulfil the requirements which derive from each application and product characteristics. The foam is light and yet stable. These features bring additional benefits in terms of transport costs and fuel consumption.
Expanded polyethylene foam packaging – design possibilities and applications
Expanded polyethylene (EPE) foam packaging stands out by firmness and shock-absorbing features. Also called PE foam packaging, it is suitable for products with greater robustness and lower fragility. Additionally, it is optimum for parts with corners and sharp edges. The material’s low weight and dense consistency offer a high load capacity. Such features provide significant economies throughout the entire supply chain.
EPE foam packaging is a recyclable solution which can contribute to a more sustainable industrial environment. We offer it extensively in automotive, electronics and most packaging applications. In these fields, durability, flexibility and repeated impact resistance are some of the base requirements. Electronic industry applications need ESD EPE foam packaging. The solution safely packs electronic components and devices.
We can convert EPE foam into various trays, inlays and compartments. EPE inserts and carved layers stand out for positioning and cushioning. They offer increased protection and transport stability for the packed goods. EPE foam inlays and trays are custom developed with cutouts that faithfully fit the products to be protected. They can guarantee a considerable number of use cycles in any industry field.
EPE foam packaging frames absorb the shocks and protect the items against damage during handling and shipping. The frames can be designed as one or several-piece items. One-piece versions can have specific extendable cutouts to adapt to parts of larger sizes. The several-piece frames join in particular settings from identical or different pieces that fit together. Due to their cutouts and hinges, companies can ship these packaging foam cushions flat (unmounted) to save space in transport.
EPE foam is also available as standard and tailor-made extruded profiles. The range includes C, L and U foam profiles and edge and corner protections. The standard profiles are available in various thicknesses and cut to your length requirements. We can also develop unique profiles based on each application’s details and restraints. Some of the profiles can have stretching features or V cuts. These characteristics make them adaptable to circular and angled products.
Polyurethane foam packaging – design possibilities and applications
Polyurethane (PU) foam packaging is light, soft, flexible and breathable. After compression, it rapidly returns to its original shape. The features create the premises of excellent shock-absorbing performance. PU foam protective packaging is suitable for securing and supporting small or less heavy products. Additionally, it can protect items with a surface finish.
The custom cuts, such as grooves and notches, protect the products from vibrations and scratches throughout the supply chain. They also optimize the number of products per packing unit and the packing unit weight. Additionally, they increase the space-savings in storage and transport.
The material can take the form of various PU packaging inserts, cushions and intermediate layers for industrial applications. Covers and dividers are all customized to accommodate and protect the components. The operators arrange them inside containers and trays. PU foam inlays provide rational storage. They offer the possibility to pack many products in the load carrier and loading unit.
Convoluted foam or egg box foam is a specific packaging solution consisting of PU foam plates with regular and repetitive peaks and troughs. Companies use it in pairs, with one layer at the top and the other at the bottom. The system encloses delicate and lightweight items. It keeps them in position during handling and transport. The main advantage of the egg crate foam is its use for different dimensioned products. So changing the insert according to the packed product is unnecessary. Convoluted polyurethane foam inserts commonly protect electronic parts. In this case, we produce them from pink antistatic material. They can accommodate sensitive electronic parts, components, equipment and instruments.
There are applications with heavier products where the packaging aspect could be less critical. In such cases, we can recommend rebound PU foam packaging. Rebound foam is manufactured from PU scraps with different densities. The result is a heavier and dense material with a mosaic appearance. This technical packaging offers advanced protection properties.
Transformation process – from foam materials to foam packaging
The vast range of the existing technical foams can tangle even experienced engineers and acquisition experts. But we have a deep knowledge of the foam materials market. Also, we add a long experience in defining our client’s packaging needs. All these allow us to flexibly choose the right solution for each dedicated project.
Our customized foam packaging development starts with a thorough analysis of each application. And it relies on detailed testing of dozens of materials and technologies. The project must undergo a complex process to create precisely fitting unique packaging. The stages include drawing, packaging development, and prototype execution. After the customer’s tests and approvals, the series production can start.
We require complete information about the product protection needs. We combine it with relevant data about existing packaging unit components. We also consider the intended number of life cycles. The procedures allow us to identify the applicable requirements for the final product. The next step is to establish a suitable foam material.
The available converting technology and machines enable us to process high-performing technical foams. We cover a wide range of polymers with various densities and features. We can slice, slit, cut, mill and CNC route (for 3D shape products) the foam. In this way, it can precisely follow the product’s shape. Additionally, the process optimizes material consumption.
Countless options and techniques are available to further improve the tailor-made foam inserts and layers. They include self-adhesive tapes and lamination. We can convert flexible materials into complex technical foam packaging. We start from a simple roll, sheet or block unit. The foam materials are available with distinct properties. These properties include fire retardancy, thermal insulation, sealing or electrical conductivity.
Features, advantages and benefits
Packaging and transport foams are designed according to our customer requirements. We also take into account the product details and constraints. In this way we can protect a wide variety of industrial goods. We achieve maximum safety and stability with minimum material usage.
Foam packaging is:
- Impact and deformation resistant
- Lightweight yet sturdy
- Suitable for sensitive or painted surfaces
- Economic as it eliminates the need to use additional fixing or protection elements
- Entirely customized packaging solution
Foam packaging stands out for:
- Fixing the product in its place
- Bracing the product
- Preventing the product from touching the package or other products
- Packaging weight reduction at optimum resistance
- High packing density
- Damage-free delivery during the most rigorous transport cycles
- Reduced shipping costs
- Rapid arranging and handling of the items in internal logistics
Foam packaging material
Plastic foams distinguish themselves by a multitude of material-coated cells filled with air. This construction makes them lightweight yet resilient. They offer superior mechanical properties. The requirements for foam packaging solutions are very diverse according to each application. Thus, we use various foam materials to meet them.
Polyethylene foams are produced with locked cells (sealed from each other). They are stiffer, denser and more durable. The structure makes them significantly resistant to wear and tear. At the same time, they have an excellent insulating role. The range comprises non-cross-linked polyethylene foam (expanded polyethylene foam) and cross-linked (XPE) polyethylene foam.
Polyurethane (PU) foams are produced with open (interconnected) cells. They are softer and more flexible than closed-cell foams. They can rapidly return to their original shape after compression. When required, we can use other foam types or blends for special projects.