Packaging foam comes in many varieties, each with its own unique properties, advantages, and drawbacks. Choosing the right foam is essential for ensuring your products arrive safely at their destination. The type of foam that will work best depends on factors like the weight, size, shape, and fragility of the items you’re shipping.
In this article, our packaging experts break down 12 of the most common types of packaging foam and explain the pros and cons of each. From lightweight expanded polystyrene to dense polyethylene, soft polyurethane to rigid polypropylene, we’ll cover foams that cushion, block and brace, or provide a custom fit.
12 Common Types of Protective Packing Foam
When it comes to protecting your precious cargo during shipping, not all foam is created equal. From the classic styrofoam peanuts to the high-tech polyurethane foam, each different type of foam packaging has its own unique set of advantages and disadvantages.
Below, our packaging engineers dive into the most common types of packing foam used today, exploring their properties, best use cases, and potential drawbacks.
Ethafoam
Ethafoam is a versatile closed-cell polyethylene foam that provides excellent cushioning and protection for a wide range of products during shipping and storage. It is lightweight yet strong, and can be easily cut to create custom inserts that fit snugly around items. Ethafoam is resistant to chemicals, moisture, dirt and mildew.
Pros:
- Excellent shock absorption and vibration dampening
- Can be cut to any shape for a custom fit
- Lightweight and flexible
- Chemical and moisture resistant
Cons:
- More expensive than some other foams
- Sheets take up storage space
- Cutting custom inserts takes time
Polyurethane Packaging Foam
Polyurethane foam is a versatile, open-cell foam that is soft, lightweight and easy to mold. It is commonly used for cushioning and protecting lightweight, fragile items during shipping. Polyurethane provides excellent shock absorption and can be cut into custom shapes to cradle products.
Pros:
- Soft and cushioning to protect fragile items
- Lightweight which reduces shipping costs
- Can be custom molded to fit products
- Good thermal insulation properties
Cons:
- Not as durable as some other foams
- Open-cell structure can absorb moisture
Polyethylene Foam
Polyethylene is a dense, closed-cell foam that offers more rigidity and durability compared to polyurethane. It has high strength and impact resistance, making it ideal for protecting heavier items in transit. Polyethylene also has good chemical and moisture resistance.
Pros:
- Durable and impact resistant
- Closed-cell structure resists moisture
- Lightweight yet strong
- Easy to cut and shape
Cons:
- Less cushioning than softer foams
- Petroleum-based material
Expanded Polypropylene (EPP)
EPP is a recyclable closed-cell foam known for its high strength-to-weight ratio. It has excellent impact absorption and thermal insulation properties. EPP is commonly used for protective packaging, especially in the automotive industry, as well as reusable packaging.
Pros:
- Lightweight yet strong and durable
- Excellent impact absorption
- 100% recyclable
- Thermal and chemical resistant
Cons:
- Higher cost than some foams
- Limited cushioning for very fragile items
Expanded Polystyrene (EPS)
EPS, also known as styrofoam, is a rigid closed-cell foam made of expanded polystyrene beads. It is one of the most common packaging materials, often molded into forms to cradle products or used as loose fill. EPS provides good impact protection and thermal insulation.
Pros:
- Lightweight and inexpensive
- Good impact absorption
- Thermal insulation properties
- Easily molded into shapes
Cons:
- Bulky and takes up space
- Made from petroleum-based polystyrene
- Not biodegradable, difficult to recycle
Cross-Linked Polyethylene (XLPE) Foam
Cross-linked polyethylene (XLPE) foam is a versatile closed-cell material known for its durability and performance. The foam is created by chemically cross-linking polyethylene molecules, resulting in a strong, resilient structure.
Pros:
- Excellent shock absorption and impact resistance
- Resistant to chemicals, moisture, and extreme temperature
- Smooth surface texture and fine-celled structure
- Performs well as thermal insulation and vibration damping material
Cons:
- More expensive than standard polyethylene foams
- Not as easily recyclable as non-cross-linked foams
- May have a slight odor due to the chemical cross-linking process
- Rough exterior may lack aesthetic appeal compared to physically cross-linked foams
Neoprene Foam
Neoprene is a synthetic rubber foam valued for its excellent insulation properties. It is moisture-resistant and provides good padding and shock absorption. Neoprene is often used as protective inserts and padding.
Pros:
- Excellent thermal insulation
- Moisture and chemical resistant
- Soft yet durable cushioning
- Lightweight and flexible
Cons:
- More expensive than other foams
- Petroleum-based material
Bio-Based Foam
Bio-based foams are an eco-friendly alternative to traditional petroleum-based foams. They are made from renewable plant materials like soy, castor or corn oil. Bio-foams can provide comparable performance to conventional foams.
Pros:
- Made from renewable resources
- Biodegradable and sustainable
- Reduced dependence on fossil fuels
- Can be composted
Cons:
- Higher cost than petroleum foams
- Newer technology, less proven
Foam Box Inserts
Custom-cut foam box inserts are designed to fit snugly inside boxes, cradling and protecting products on all sides. They prevent items from shifting in transit and provide excellent impact resistance. Foam inserts are especially useful for shipping fragile components.
Pros:
- Holds items securely in place
- Excellent impact and vibration dampening
- Can be cut to any shape for a custom fit
- Professional presentation
Cons:
- Requires custom design and cutting
- Can be bulky and increase shipping size
Anti-Static Foam
Anti-static foams are specially engineered to protect sensitive electronic components from electrostatic discharge. The foam dissipates static buildup, preventing damage to electronics during shipping and handling.
Pros:
- Protects electronics from static
- Cushions against impacts
- Available in various densities
Cons:
- More expensive than standard foams
- Slightly conductive, not for all uses
Pre-Assembled Styrofoam Shipping Boxes
Styrofoam shipping boxes provide an easy, ready-to-use packaging solution for items that need impact protection during transit. The molded styrofoam inserts cradle products securely and the outer corrugated box provides stacking strength. Commonly used for electronics and other fragile goods.
Pros:
- Ready to use with no assembly required
- Reliable impact protection
- Stackable for efficient shipping
- Lightweight compared to molded plastic
Cons:
- Not easily customizable
- Limited range of stock sizes available
- Styrofoam can break
Suspension Packaging
Korrvu® suspended packaging holds products between two layers of highly resilient low-slip film, keeping them securely in the center of the shipping box to isolate them from shock and vibration. This innovative solution showcases products with a clear view while providing excellent protection, creating an enhanced customer unboxing experience. Ideal for fragile items like electronics.
Pros:
- Suspends and cushions products for superior protection
- Crystal clear film showcases products
- Low-slip film holds items securely in place
- Lightweight and uses minimal material
Cons:
- Designing custom Korrvu insets has higher MOQ
- Applying suspension film requires some labor
- Not suitable for very heavy items
- Some products may not fit standard sizes
What to Consider When Choosing the Right Foam
The fragility, weight, and dimensions of your items should guide your foam choice.
Delicate goods require superior shock absorption, while heavier products need denser foam for robust support. Match the foam type to your specific packaging demands for the best protection.
Here are the key considerations for choosing the perfect foam materials for your packaging applications:
- Fragility: Assess your product’s vulnerability to damage. Highly fragile items like electronics need foams with excellent shock absorption, such as polyethylene or polyurethane.
- Weight and size: Heavier, larger items require denser foams like polyethylene for stability. Lightweight, smaller goods benefit from the cushioning of softer polyurethane foams.
- Budget: Compare costs of different foam options. Expanded polystyrene (EPS) is economical for less delicate items, while cross-linked polyethylene (XLPE) offers premium protection at a higher price point.
- Sustainability: Opt for eco-friendly foams like biodegradable or recycled materials to minimize environmental impact, especially for green-conscious brands.
Protect Your Fragile Products with Custom Packaging Design from Creopack
Choosing the right packaging foam for your products can make a big difference in ensuring items arrive safely at their destination. While each type of foam has its own set of pros and cons to consider, sometimes an off-the-shelf solution doesn’t provide the optimal level of protection for uniquely shaped or highly fragile items.
The packaging engineers at Creopack specialize in creating tailored foam packaging that perfectly cradles and cushions your products during shipping. Using advanced equipment and materials, we can fabricate custom-cut foam inserts based on the exact dimensions and protection needs of what you’re shipping.
Don’t leave the safety of your valuable goods to chance. Reach out to the experts at Creopack to discuss a bespoke protective packaging solution precisely engineered for your products.