If you need basic, low-cost protection for your products, foam blocks can be a good choice.
Foam blocks are one of the simplest forms of foam packaging. Essentially pre-cut blocks of foam material, they are used within an outer shipping carton to brace and cushion products during transit. Available in standard sizes, and often self-adhesive, foam blocks are also available in bespoke sizes and a range of material grades and options.
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 just like yours for well over 40 years.
Although a fairly basic option, foam blocks still provide several benefits:
Polyethylene (PE) foam is the material packaging manufacturers commonly use when producing foam blocks. This is due to its strength, various densities, and overall cushioning performance. Polyurethane (PU) is also sometimes used for lighter items requiring less cushioning.
While cheap, lightweight, and still widely used, Expanded Polystyrene (EPS) is highly brittle and cracks easily under repeated impacts, losing its protective qualities after a single drop. It is also bulky to store, difficult to recycle (and not accepted through standard kerbside programs), and breaks down into harmful microplastics.
Foam blocks are among the most basic types of foam packaging. Not being tailored to a specific product, they are suited to shipping large items of varying shapes and sizes. However, they offer less protection than tailored packaging options such as foam end caps or moulded foam packs.
Cubed (or pick-and-pluck) foam is a pre-scored foam block divided into a grid of small, easily removable cubes. It is typically used within protective cases rather than in single-trip packaging applications. It allows users to customise the interior equipment case without tools, using their fingers to pluck out cubes to match the exact shape of the item(s) being transported.
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.
With over 40 years of industry experience, a skilled engineering team, and an advanced UK factory, we create the exact custom foam blocks, inserts, and packaging your business requires.
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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