If you need a versatile foam packaging option, egg crate foam is ideal for shipping varying items within a standard outer pack.
Egg crate foam, also commonly called convoluted foam, is a packing material which features a repeating pattern of peaks and troughs. It is often used in protective case lids and foam-lined boxes. Typically made from soft, open-cell polyurethane, it works by sandwiching the contents of the pack, with the peaks then compressing to hold items in place. By limiting movement, alongside the inherent cushioning provided by the foam, egg crate foam is a good option for protecting items of different sizes and shapes during shipping.
Regardless of your industry, application, or products, at Polyformes, we can design and manufacture a foam packaging solution that delivers optimal performance and cost. In fact, we have been doing just that for businesses like yours for well over 40 years.
Egg crate foam provides several benefits, including:
In the packaging industry, egg crate foam is also known as convoluted foam. It gets this name from the manufacturing process, which uses specialist rollers and blades to create a repeating pattern of peaks and troughs.
Egg crate foam is popular for packaging applications for several reasons. Firstly, its convoluted design conforms to irregularly shaped and sized items. Secondly, it braces products to prevent them from moving during transit. Thirdly, it absorbs shock during transit, and finally, it provides lightweight, cost-effective cushioning without the need for expensive custom-cut inserts. It is commonly used in foam-lined boxes for this reason.
Most egg crate packaging uses an open-cell polyurethane (PU) foam. This material is suited to egg crate foam for its softness, flexibility, and excellent shock-absorption qualities. It is also non-abrasive, meaning it does not scratch or mark delicate surfaces like glass or polished metal.
Standard egg crate foam is not anti-static, but several conductive and anti-static grades are available. Usually dyed pink, anti-static convoluted foam features specialist compounds which help prevent electrostatic discharge (ESD). These properties make it ideal for shipping sensitive electronics and circuit boards.
We don’t just manufacture egg crate foam – 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.
With more than four decades of trade expertise, a dedicated engineering team, and a cutting-edge UK conversion facility, Polyformes can provide the exact foam packaging, inserts, or products your business needs.
UK manufacture
Short lead times
Foam experts
Single source
Vast experience
Sustainability
Disclaimer: Generative Ai may be used on this site when specifically creating content and information relating to the products, processes and materials we use at Polyformes. Any Ai content undergoes stringent reviews and editing by humans to check accuracy. Please view this content policy for further details.
Send us a message
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.
This form will collect your personal information to answer your enquiry. For information on the data we collect and how we use your information, please see our privacy policy.
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.
Sales Enquiries
[email protected]
01525 852 444 (option 1)
Accounts Enquiries
[email protected]
01525 852 444 (option 2)
