Moulded foam packaging is a great option when considering performance, aesthetics and cost.
Moulded foam packaging is a type of insert or pack in which the foam is heat- or thermo-formed to the exact contours of the products it is to protect. As well as preventing movement during transit, moulded foam packaging also absorbs shocks, impacts, and vibrations and can enhance appearance. Although moulded foam packaging sometimes refers to expanding foam, the more popular option is pre-moulded inserts used within an outer container (such as corrugated packaging or plastic cases).
At Polyformes, we have extensive foam moulding equipment. Combined with our material knowledge and design expertise, it enables us to create moulded foam packaging tailored to your product’s contours.
Moulded foam packaging offers a range of benefits and advantages:
Moulded foam packaging is a lightweight, custom-engineered protective material shaped to fit a product’s exact dimensions. Manufactured from polymers such as expanded polystyrene (EPS) or polyurethane, it cushions high-value, fragile, or heavy goods from shocks, drops, and vibrations during transit.
Moulded foam protects products through controlled deceleration. Fitting tightly around an object prevents it from shifting or colliding with the outer box walls. When a package experiences forces (such as being dropped), the air-filled cells in the foam absorb and dissipate the kinetic energy away from the item.
The majority of moulded foams are recyclable. Materials such as expanded polystyrene (EPS) and molded polyethylene (PE) can be compressed and melted into new plastic products. However, they are not currently accepted in UK kerbside recycling collections, instead requiring drop-off at specialised commercial recycling centres.
Moulded foam is better for high-value, fragile, or heavy items requiring maximum shock absorption and moisture resistance. Moulded pulp (recycled fibre) is preferred when environmental sustainability, biodegradability, lower raw-material costs, and minimal storage space are the primary requirements (and where a high degree of protection is not required).
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.
If you need foam – of any type – Polyformes is your single point of contact. With more than 4 decades of experience, a team of experts, and a modern UK production facility, you can rely on us for quality, expertise, and cost-effectiveness.
UK manufacture
Short lead times
Foam experts
Single source
Vast experience
Sustainability
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If you need high-performance foam inserts, packaging, products or materials, we can help. Please contact a member of our team for a free consultation and quote.
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Our experts
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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