3 Reasons to Use Foam Packaging


While paper and plastic are the standard go-to for packaging, foam is often the better choice. There are three key reasons why.

1. Packaging Foam is More Cost-Effective

A common reason why businesses choose box and void fill is because of the initial cost. On paper (no pun intended) paper is cheaper per unit - that’s true. 

However, when you look at what you get for your money and long-term protection, foam is much more cost effective. Firstly, foam is much better at protecting a product using less material. So while paper might be cheaper, you often end up spending more because the amount of material it takes to adequately protect a package is so much greater. 

Additionally, the extra protection that custom foam inserts provide improves the likelihood of a product arriving undamaged. If a package arrives damaged, your costs skyrocket (not to mention the goodwill lost from the customer). In both cases, foam is more cost-effective than paper and plastic packaging options.

► Related Content: Case Study: Ship in Own Container vs. Box in a Box

2. Packaging Foam is Customizable and Versatile 

Another advantage of foam packaging is how customizable and versatile it is. A foam case insert is custom-built for your product and can be replicated endlessly for future use. 

Additionally, you can play with color, texture, laminate, rigidity and form to create a compelling unboxing experience without sacrificing protection. You can even print designs or text right onto the surface of your foam insert, which opens up even more possibilities. The design options are limitless with foam.

► Related Content: 5 Foam Packaging Ideas to Make Your Product POP

3. Foam Packaging is Sustainable

In recent years, there’s been big consumer awareness campaigns for the recyclability of paper and plastic - but not foam. 

It’s not that foam isn’t sustainable - it’s just not as widely adopted for end-user recycling like paper and plastic are. However, that’s not the only factor that goes into sustainability. Foam is more sustainable when you look at the carbon impact from manufacturing and shipping.

The biggest impact foam has is on manufacturing impact. Producing polyethylene foam takes less energy than non-plastic alternatives. Additionally, it drastically reduces the environmental impact caused by damaged products.

Each damaged product that has to be replaced has the following effects, on average:

  • 01 pounds of methane gas emissions
  • 01 trees
  • 13 square feet of natural habitat lost
  • 8 kilowatt hours (kWh) of electricity
  • 1,697 British thermal units (BTUs) of heat produced
  • 7 gallons of fuel
  • 10 pounds of solid waste in landfills
  • 4 pounds of carbon dioxide gas emissions

(Source: Pregis)

Foam avoids all of that by ensuring a product arrives undamaged. Finally, foam can be recycled - even if not all cities yet support end-user recycling.

► Related Content: Our Resource Guide to Educate End Users on Recycling Foam

Find Your Best Option with a Packaging Expert

As a leader in the packaging industry, Foam Industries has set the bar with an unwavering commitment to quality, exceptional client service, and constant innovation. Through our extensive inventory of endlessly customizable products, we ensure you find exactly what you’re looking for.

Contact a Packaging Expert 

Foam Industries is a custom protective packaging company specializing in foam – with additional wood and plastic fabrication services. Our custom foam fabrication services are ideal for any type of packaging, display, or support service needed – from design to finished product.

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