If you send a variety of items that require cushioning, foam-lined boxes are a great option.
Foam-lined boxes are cardboard shipping boxes with a foam lining on the interior, typically on the base and lid. Often using an egg crate or convoluted foam, the lining prevents the contents from moving while also providing cushioning protection. The main benefit of this type of pack over options such as foam end caps, which are tailored to a specific item, is that the foam-lined boxes can accommodate products of varying sizes and shapes.
At Polyformes, we can supply foam-lined boxes in almost any format you require. We can tailor the size, material grades, performance, and appearance of your packaging, or alternatively, supply a range of stock options as part of Macfarlane Packaging.
Foam-lined boxes offer several benefits for your business, including:
The primary use of foam-lined boxes is to protect semi-fragile, expensive, or sensitive items during shipping. The foam interior braces the contents, while also absorbing shocks, vibrations, and impacts that may occur when in transit. They are particularly suited to applications where the product (or combination of products) varies in size or shape from one order to the next.
The two most common types of foam used are Polyurethane (PU) and Polyethylene (PE). Polyurethane is soft and flexible, making it ideal for cushioning lightweight, delicate items. This material is also typically used to create the “egg crate” foam often used in foam-lined boxes. Polyethylene is also commonly used but is denser and more rigid, making it ideal for bracing heavier products or sensitive electronics.
While the cardboard box itself is easy to recycle, standard packaging foam is usually made from polyurethane, polyethylene or expanded polystyrene, which end users cannot recycle in kerbside bins. To recycle them properly, individuals should separate the foam inserts from the cardboard and take them to specialist recycling centers.
Egg crate foam, also known as convoluted foam, is a type of material where the surface features an undulating pattern. When used in a foam-lined box, the peaks come into contact with the contents and help to prevent them from moving around during shipping.
We don’t just manufacture foam packaging – we gain a detailed understanding of our business and challenges before proposing a cost-effective solution that does exactly what you need.
Understanding
We discuss your requirements with you, gaining a full, detailed understanding of your project.
Develop
Using your products or CAD data, we develop a solution using appropriate materials.
Test
We provide pre-production samples for testing and assurance on fit and quality.
Manufacture
We manufacture your inserts in-house at our specialist foam conversion facility.
Support
We forge long term relationships, providing ongoing support and assistance.
Most foam-lined box suppliers only offer a range of stock options. Whilst we can also do this – through our parent company, Macfarlane Packaging – our expertise and manufacturing capability enable us to manufacture foam-lined boxes to your exact specification.
UK manufacture
Short lead times
Foam experts
Single source
Vast experience
Sustainability
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The information on this page was written and checked by our team of experts. You can contact them to discuss your requirements, or for any questions you may have, using the details here.
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