What do medical equipment, military optics, computer monitors, and small home appliances all have in common? They are all products that need to be protected during shipping. Whether it’s from scratches, vibrations that can knock sensitive connections loose, or drops that can damage or break fragile items, manufacturers seek a cost-effective solution for protecting products. Foam is this solution! Foam, a highly versatile material when used in corrugated boxes, reusable plastic cases, and wooden crates, offers many advantages. This post will look at the benefits of using foam packaging materials.
Absorption of Shocks and Impacts
You probably learned about Sir Isaac Newton’s First Law of Motion, known as inertia, back in high school. If you remember, Newton’s Law says, “An object at rest remains at rest, and an object in motion remains in motion at constant speed and in a straight line unless acted on by an unbalanced force.” You may not have thought it essential knowledge back then, but if you are transporting products without proper protection, you will quickly see the importance. You want the opposing force to be packaging foam that will cradle your product in place and protect it from outside forces.
No matter how a product is shipped, the trip is never smooth. Packages can be subjected to a variety of rough motions and forces that may cause damage if the product isn’t protected.
- Handling – Products may be dropped or shaken by the handlers. If stacked hastily and improperly, they may face impact or excessive compression. Proper foam packaging can provide rigidity and strength.
- Air transportation – Turbulence during flight can cause shaking, acceleration and deceleration during take-off and landing can cause shifting in the package, and pressure changes can pop air pillow protection or bubble wrap. Foam can provide protection and isn’t impacted by altitude changes.
- Train transportation – Vibration from the tracks can resonate through the packaging, coupling of cars or sudden stops can cause impacts to products, and shifting can occur if the cargo isn’t adequately fastened. Foam provides a layer of protection so that bumps and jostling won’t damage your product.
- Ship – Rolling and pitching from sea waves can be violent during storms, causing the product to move around within the packaging. Sea salt and moisture can damage products that are packaged in paper packaging. The right foam choice offers cushioning and protection against moisture and salt.
- Trucks – Uneven road surfaces and potholes can cause bouncing and vibrations. Acceleration, deceleration, and cornering can cause shifting within the packaging. If the load isn’t properly secured, products can fall over. Packaging foam can prevent damage to products during transport.
Naturally Light Weight
Foam can be up to 90 percent air, making it a naturally lightweight material. Being lightweight is advantageous to you and your customers. Lightweight packaging costs less to ship. You may also be able to reduce packaging size, which means more products will fit in a truckload, so you may be able to ship with fewer truckloads, reducing carbon emissions.
You can significantly lower the package weight by opting for foam to protect your product. Lighter-weight packaging is easier to handle, putting less strain on your warehouse employees, shipping personnel, and customers.
Customization and Versatility
Foam is so versatile because there isn’t a one-type-fits-all solution. Foam can be broadly described as open cell (interconnected pores) or closed cell (closed pores), which may be flexible or rigid. The variations of foam provide unique qualities (and benefits), affording versatility to suit an array of applications. Different options for foam packaging include:
- Polyurethane (PU) is an open-cell, soft, versatile foam that can be easily fabricated to fit different products. It is often used for cushioning and vibration dampening and can be used to create protective inserts for delicate products.
- Polyethylene (PE) is a closed-cell foam that is more resistant to moisture and chemicals. It is often used for cushioning and vibration dampening, such as cushioning and protecting small appliances during shipping. It can also be used to create protective liners for shipping boxes and crates.
- Expanded polyethylene (EPE) and expanded polypropylene (EPP) are types of foams made from tiny beads of polymer that are expanded and fused. They are lightweight and have good vibration-dampening and cushioning properties. They are resistant to moisture and chemicals. EPE and EPP can be used to create custom liners and can be molded. It is used for a variety of products, including sporting goods, auto parts, and industrial products. In most cases, EPE and EPP are fully recyclable.
- Cross-link is a closed-cell foam that has undergone a chemical or physical process to create stronger bonds between the polymer chains. This enhances the foam’s strength, temperature resistance, and chemical resistance. Both open and closed cells can be cross-linked to improve performance attributes. Cross-linked foams used for packaging include polyethylene and ethylene-vinyl acetate. Cross-linked polyethylene and ethylene-vinyl acetate foam have smooth surfaces and provide good shock absorption, vibration dampening, and chemical resistivity. It is often used to package sensitive items such as electronics and medical devices and used in case and tool inserts.
- Reticulated foam is a highly porous open-cell material with a net-like structure – the cell membranes have been removed, leaving behind a skeletal frame. While several types of reticulated foams exist, polyether is most often used as packaging. This foam is often used for applications where superior shock absorption and vibration dampening, moisture resistance, chemical resistance, and mildew resistance are required. It is also a relatively inexpensive and easy-to-process material.
With so many options to choose from, your foam packaging can be customized to your product and its needs, ensuring it remains cushioned and costs are affordable.
Cost-Effectiveness
Packaging foam is a cost-effective method for protecting your products. We’ve already mentioned how it can reduce shipping costs. Additionally, with packaging foam, you will mitigate the risk of product damage, returns, and warranty claims, which can add costs. Customers who receive products that have been damaged during shipping are less likely to purchase from you again and may leave poor reviews that can impact future sales.
Recyclable
Many types of foam can be recycled and made into new products. For example, PU foam is repurposed and used by carpet pad manufacturers, white PE foam is recycled and used for trash bags and bins, EPE foam can be melted and made into granulate PE pellets and used to make other products, and PU packaging can be recycled to create insulation and high density panels.
Ready to Try Foam Packaging? WIC Can Help!
With so many benefits to using foam, now is the time to consider it. Our engineers will design packaging that fits your unique needs, providing you with a solution you can trust. Call us today and get started!