Foam, an unsung hero in packaging solutions, is more than just a simple cushion for your products. Whether you are packing an item worth a fortune, or shipping a fragile keepsake, the right foam can make all the difference between it arriving intact or in pieces.
In this article, we will explore the different types of foam available for your packaging needs, and help you understand their unique properties, strengths, and potential applications.
Foam is one of the most versatile and widely used materials for protecting and cushioning products that require special handling and ultimate protection.
There are many foam types, and a wide variety of thicknesses and densities, as well as those with anti static or fire retardant properties that are available to meet your specific application.
It is vital to ensure that the foam used will be dense enough to absorb the impacts and shocks that your investment may encounter on the journey to its final destination.
The type of transportation including the class of the courier and the distance to be traveled are influential factors when selecting the type, thickness and density of foam that will best protect your product.
Foam is a cost-effective packaging solution as it is one of the most lightweight packaging materials, keeping freight costs to a minimum.
Also, almost all foam types are recyclable and reusable, it can be melted down and reused or even remolded for similar applications.
The main industrial foam used in wooden crates and large boxes is generally white or black, however, foam is available in a vast amount of colours which unquestionably assists in facilitating an unforgettable first impression.
If you are looking to line a smaller carton or plastic case with foam, brighter colors like red or blue make a bold visual statement.
Foam with fire retardant properties can be utilized in packaging applications, as well as inside electronic equipment, to protect batteries, provide vibration and shock protection for sensitive components, and many more applications including sound insulation. These foams are often used to prevent damage during transportation or storage of lithium iron batteries. These foams comply with regulations such as UL94 V-0, HF1, Mil-Spec CID-A-A-59136, as well as many other ASTM and Mil-Spec requirements.
Static protecting foam types shield sensitive components from electro-static discharge as well as physical damage, they are ideal for protecting electronic parts during storage or shipment, transporting fragile non electronic components into static controlled environments, for work in progress trays for items such as circuit boards, and more. Generally these foam types are broken into 3 different categories; conductive, anti-static and static dissipative.
Conductive, or static shielding foam, allows static charges to quickly dissipate, preventing any static build up, it is usually black in colour. It is used to create what is known as the faraday cage around a product, so that it does not have to go into a static shielding bag for the product to be appropriately protected. This is a great material for reusable solutions.
Anti-static foam is usually pink in colour, it prevents a static charge from building up when rubbed, (either by the packaged part, or another piece of foam). However, static charges can still pass through it, so to create a static free environment a static shielding bag is also required.
Static dissipative foam falls between conductive and anti-static, it allows static charges to slowly move to the ground, preventing sudden static shock from occurring.
Samples of our work and the different types of foam are available upon request
SmartShield Packaging take pride in making our customers smile with packaging done right. Our dedicated team are always happy to share their knowledge of the products available, and their creative expertise to assist you in achieving an impeccable package design.
With specialized equipment that can cut, shape and glue foam, you can be assured the perfect nest required to keep your product safe through every step of its voyage will be created.
No project is too challenging for the team at SmartShield. From a simple foam set to cushion a component in a cardboard box, to a complex foam set to protect multiple items in a plastic case, the perfect package will be produced.
Presentation matters and customer satisfaction is paramount, our passion is providing you with a first-rate package that will complement the item or items, and undoubtedly impress your recipient, and this is accomplished with a team offering skill, design creativity and years of experience.
Polystyrene or EPS (expanded polystyrene) is a firm closed cell foam, also known as styrofoam. It is the most cost-effective option of all foam types.
Polyethylene foam is a closed cell foam, its structure provides robust strength and resilience, allowing it to return to its former shape after compression.
Polyethylene foam is very versatile, it comes in various thicknesses, densities and styles, and has multiple uses including insulation and packaging of large and small, heavy and light products, for a single use or a reusable package.
It usually comes in black or white and with anti-static properties in pink. It is also available with fire retardant properties. Polyethylene foam is easy to cut, glue and heat seal and, can be laminated to itself to provide thicker sections for specialized custom package designs.
Polyurethane foam is an open cell foam, generally a more flexible foam than polyethylene. It is often used in custom design packaging to cushion breakable items, but also as carpet underlay or for comfort and support in home furnishings, or in the automotive industry for chair cushions.
Both polyethylene and polyurethane are more expensive options than polystyrene (EPS) but also more cost effective than crosslink options, if class A surface protection is not required.
Our recommendation is polyurethane for smaller, lighter product use, and its softer material characteristics are ideal for delicate items requiring higher surface protection.
While polyethylene is excellent for heavier product usage and does not absorb water due to its closed cell design.
Crosslink also known as XLPE, is a closed cell foam. Polymers are chained together and heated to give it the cross-linked structure, offering superior strength and chemical properties to standard polyethylene foam.
Zote foam is a brand of crosslink foam so it is a closed cell, superior quality foam that also offers class A surface protection, meaning it is safe to use with painted product.
Expanded Polyethylene, also known as EPE, is another foam option to replace crosslinked foams. This material still provides class A surface protection but is easier to recycle than crosslink.
Understanding the various types of foam available for packaging can help you make an informed decision for your specific needs.
Whether you're after the rigidity of polystyrene, the resilience of polyethylene, or the flexibility of polyurethane, each type of foam has its unique strengths and potential applications. High-end options like Crosslink and Zote offer exceptional durability and Class A surface protection, making them the preferred choice for long-term performance and repeated use.
EPE, with its environmentally friendly profile and capacity for high shock absorption, is a compelling alternative to standard foams. With the right foam selection, you can ensure your product is protected, your package design is impeccable, and your shipping costs remain minimal.
SmartShield's commitment to premium quality and customer satisfaction means you can trust us to provide the perfect foam packaging solution for your precious products. We believe in the power of foam to safeguard your items on every step of their journey, providing the ultimate peace of mind.