Foam packaging

Plastic foams are distinguished by a multitude of material-coated cells filled with air, either sealed from each other (closed cells foams) or interconnected (open cells foams). The closed cells foams are stiffer, denser and more durable, making them suitable for shock absorption applications. At the same time, they have a very good insulating role, because they do not allow air circulation and are likely to absorb water only on the edge. Some examples of closed cell foams include non-cross linked polyethylene foam (also called expanded polyethylene foam – EPE foam) and cross-linked polyethylene foam.

Closed cells foams are significantly resistant to wear and tear. They are more suitable for exposed use indoor and outdoor and have few limitations in terms of possible additives. Becouse of the higher material content, closed cells foams are consequantly having a less-economic cost than the open cells foams.

Open cells foams, on the contrary, allow the air circulation and can absorb water. They are softer, more flexible than closed cell foams and have the ability to rapidly return to their original shape after compression. This category includes flexible polyurethane (PU) foams and one of their most vulnerable points refers to the surface, which is easy to be damaged. Also, they can be used outside only if covered becouse they can be affected by UV radiation, CO2 and moisture. Unlike closed cells foams, the open cells foams offer a more limited range of colors and compatible additives.

Polyethylene and polyurethane foams are the ones we use most in developping our foam packaging solutions but, for special projects and also depending on the application, we can use other foam types or blends as well.

  • Cross-linked polyethylene foam packaging

    Product information

    Cross-linked polyethylene foams are distinguished by a smooth surface which provides a more atractive visual appearance and enhances the packed product presentation. Compared to EPE foam, they have smaller cells size and a more compact appearance. Through their closed cells structure, cross-linked polyethylene foams withstand high pressure and offer stability to the protected parts as well as an outstanding schock-absorbtion.

    The cross-linking process is adding extra resistance to the material by joining polymers that wouldn’t normally stick together. Depending on the production method, this material can be divided into chemically crossed linked PE foam (also called XLPE) and physically cross-linked PE foam (also called IXPE foam – irradiated cross-linked PE foam). IXPE foam features a regular closed cell structure with a bit larger pores than the ones of the XLPE. However, it offers superior mechanical properties and a greater potential for reuse as well as for recycling.

    Both materials are strong and resilient and can withstand moist, chemical substances and extreme temperatures. Due to their multi-purpose character, they are widely used in most industrial fields. In our crosslinked PE foam packaging we employ them to protect sensitive and valuable goods, especially in automotive and electronic industries. The materials may incorporate flame-retardant or self-extinguishing additives, as well as additives with either limited or permanent conductive features.

    Crosslinked PE foams offer packaging weight reduction at optimum resistance and are most suitable for applications where protective and aesthetic aspects are of major importance. Their technical performances ensure a damage free delivery during the most rigorous transport cycles therefor we use it including for scratch-sensitive and painted parts, as well as for items with surface treatment.

    For designing and constructing our foam packaging, we carefuly analyze each application to be able to propose the right material and to choose the manufacturing technology. We can slice, cut, mill as well as laminate the foams either in multiple layers or with different films. When we laminate the foam itself, the individual layers can be clearly seen but the resulting piece of foam provides an even greater load bearing capacity and a long life span for the final packaging.

    We offer you a large variety of reusable packaging foam separators and inserts that ensure the right support of the products. The foam packaging is calculated according to our customer requirements and product specifications to achieve maximum safety and stability with minimum material usage. Car dials, grills, spoilers and windscreens are just few of the products that can be safely packed and shipped using our technical foam packaging. Moreover, if no action is taken on them, these foam products can be reused as long as the packing unit is included in a sustainable logistic loop.

    Our individual foam inlays are worked out with precise contour from the plank to offer the right protection of the items and keep them securely in place. They separate and organize the components or subassemblies in one single primary package which can be reused multiple times. The packing, transport, storage and unpacking of the goods are thus running more quickly than with comparable processes using disposable packaging.
    Foam inserts and separators can also be welded on plates and trays made from rigid or aired plastic sheets. These are shaped under the form of small carved foam blocks that touch and support the parts in only few key points. In this way, the parts remain suspended and kept in place at a certain distance from each other.

    Tools in automotive, electronics, aerospace and other manufacturing fields must be arranged in a compact and easily accessible manner to enable smooth internal processes. Our customised tool inserts can store them in a separate way and without using much space. Thus, they provide order and a clear overview of the content inside cases, containers and drawers. They also prevent sharper tools from touching each other and therefore avoid scratches and other damages. Each item has its individual storage visible place so the operators do not have to look for them, saving important time in daily activity. At the same time, the two-contrasting colour design allows them to visually control the tool set and rapidly notice if any tool is missing.

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  • Non-cross linked polyethylene foam packaging

    Product information

    Non-crossed linked polyethylene foam, often simply called EPE or PE foam, is distinguished by closed cells that can be clearly seen and felt under the form of tiny air bubbles of at least 1 mm diameter. Some of the EPE foams are produced with a softer cell structure which offers similar performances to those of traditional cross-linked materials. All packaging composed from these fine cell polyethylene foams provide a reliable scratch protection for highly polished or painted surfaces.

    Due to its firmness and schock absorbing features, EPE foam is more suitable for packing products that have a greater robustness and an average or lower fragility, as well as for parts with corners and sharp edges. The balanced ration between elasticity, compression strength and dimensional stability makes the non-cross linked polyethylene foam packaging a high-performing cushioning protection against repeated impacts. Also, it will not break if it is bended and will return to its original shape. The closed inned cells structure offers scratches resistance and maintains its physical properties between large temperature ranges.

    We use a wide range of densities, thicknesses, colours and properties to offer you relevant EPE foam protective packaging for your products. We can split, cut, laminate and mill the material with high precision to tightly fit any shape of product, without using additional fixing or protection elements. This will offer your application a maximum space optimisation in handling, storage and transport. Furthermore, due to the low weight and dense consistancy that offers high load capacity, this foam requires a small amount of material usage in the packaging construction and provides important economies throughtout the entire supply chain.

    EPE foam can be converted into a wide variety of trays, inlays, compartments and frames that offer increased protection and transport stability for the packed goods. All EPE foam inlays and trays are custom developped with cutouts that faithfully fit the products to be protected. EPE inserts and carved layers are used for positioning and cushioning and can guarantee a considerable number of use cycles in any industry field.

    EPE foam packaging frames are intended to absorb the shocks and protect the items against damages during handling and shipping. The frames are cut from single or multi-layer EPE foam planks and can be designed in the form of one piece or several pieces item. The one-piece version can also be provided with specific cut-outs that makes it extandable and thus can adapt to parts of larger sizes. The foam frames made from several pieces can be joined in specific settings from one type parts or different frames that fit together. Due to their cutouts and hinges, these packaging foam cushions can be delivered flat (unmounted) to save space in transport.

    EPE foam packaging is a recyclable solution which can contribute to a more sustainable supply chain. We offer it extensively in automotive, electronics and most packaging applications where durability, flexibility and repeated impact resistance are some of the main conditions that must be met. In electronic industry, we employ the pink antistatic version for our ESD EPE foam packaging that are dedicated to pack electronic components and devices.

    EPE foam is also available as standard and tailor made extruded profiles (U, L and C type, as well as round shape and specials), edge and corner protections. The standard profiles can be offered in various thicknesses and cut to your own length requirements. We can also develop special profiles based on your application details and restrains. Some of the profiles can be provided with stretching features or V cuts which makes them adaptable to circular and angled products.

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  • Polyurethane foam packaging

    Product information

    Polyurethane foam, also called PU foam, is a light, soft, flexible and breathable material. Due to its open cell structure and unrestricted air movement, it can be easily compressed and then naturally recovers to the original shape. These features create the premises of a good schock absorbing performance which is suitable for protecting and supporting smaller or less heavy items as well as products with a surface finish. Their lightweight attributes optimise the overall packing unit load and generate reduced shipping costs.

    The wide range of available densities allows us to transform this foam into a large variety of PU packaging inserts, cushions and layers for industrial applications. Though these cannot be used for packing items with sharp edges, they can protect a wide variety of industrial goods, offering a safe handling, transport and storage for them. Each of our foam packaging is customised according to the needs and constrains of our clients in regards to their goods safety and their requirements for optimizing the overall packing unit. We can also combine foams with other materials from our range and we can design the complete packaging solution additionally consisting of standard or tailor made crates, pallets and pallet lids.

    PU foam inlays offer the possibility to pack a high more products in the load carrier as well as in the loading unit, providing a rational storage. The custom cuts, such as grooves and notches executed according to the requirements of the application, allow the products to be protected from vibrations and scratches throughout the entire supply chain. This also allows the optimization of the number of products per packing unit as well as increased space-savings in storage and transport.

    PU foam protective packaging allows a rapid arranging and handling of the items in internal logistics, as well as an easy movement between consecutive production processes. Inserts, intermediate layers, covers and dividers are all customised to acomodate and protect small components and can be placed inside containers and trays.

    Convoluted foam, also known as egg box foam, is a specific packaging solution consisting of PU foam plates with regular and repetitive peaks and troughs. Used in pairs, with one layer at the top and the other at the bottom, the system encloses delicate and lightweight items and keeps them in position during handling and transport. The main advantage of the egg crate foam is that it can be used for different dimensioned products and there is no need to change the insert according to the packed product. Convoluted polyurethane foam inserts are commonly used to protect electronic parts, in which case we produce them from pink anti-static material. ESD PU foam can be furthermore converted into a wide tailor-made variety of foam packaging and cushioning to accomodate sensitive electronic parts, components, equipment and instruments.

    For applications where the products are heavier and the packaging aspect is not very important, we can design rebound PU foam packaging.  Rebound foam is manufactured from PU scraps with different densities, which are chopped, blended with adhesive substances and pressed into a mould. The result is a heavier and dense material, with mosaic appearance, which can be transformed into a techincal packaging with advanced protection properties.

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Converting possibilities

The vast range of the existing technical foams can easily tangle even the more experienced engineers and aquisitions experts. A deep knowledge of the foam materials market and the long experience in defining our clients packaging needs allow us to flexibly choose the right solution for each dedicated project. Our customised foam packaging is based on a thorough analysis of each application, detailed testing of dozens of materials and technological procedures and well as on a complex design process.

We allways require complete information over the product protection needs, on the existing packaging unit components as well as on the required number of life cycles. This allows us to identify the relevant requirements for the final product, to establish the suitable foam material, to choose the suitable manufacturing technology and finally to convert the material into reliable packaging solutions.

The available converting technology and machines enable us to process high-performing technical foams from a wide range of polymers and with a wide variety of densities, hardnesses and features. The foam can be processed by slicing, slitting, cutting, milling and CNC routting (for 3D shape products) so that it can precisely follow the shape of the products which need to be protected and thus optimize the cutting operations and the material consuption.

Countless options and techniques, such as self-adhesive tapes and lamination, are available for further improving the tailormade foam inserts and layers. The lamination is the technique of adding layers to a material with the purpose of achieving improved strength, more attractive appearance or other specific properties. In a complex and precise production process, the materials are combined using double-adhesive tape, dispersion glue or hot melt-glue. Multiple layers of foams can be thus joined together for reaching non-standard required thicknesses and different combinations in terms of densities and colors. Other lamination processes are possible when using foam with aluminium, fabrics or different foils.

We can convert a great choice of flexible materials from a simple roll, sheet or block unit into a complex technical foam packaging. The foam can be provided with different properties such as fire-retardancy, thermal insulation, sealing or electrical conductivity.