When it comes to protecting products in transit, guesswork isn’t enough. Foam packaging isn’t just another option: it’s science-backed, data-driven protection. Unlike other packaging materials like paper and void-fill, we can use mathematics to calculate exactly what type, how much, and what shape of foam you need to protect your product.
Here’s the science behind why it protects better.
Obviously, packages get damaged by falling or extreme movements and jostling, but there’s more to it than that. Packages don’t just break because someone drops them. Damage can come from multiple factors:
Foam packaging is designed to account for all of these factors, providing predictable, calculated protection for your products.
If you’re wondering why foam works to protect your goods and how it does such a good job, we’re here to discuss the science behind the packaging. Let’s talk about cushioning curve, foam tensile strength, and ILD/IFD (if these words mean nothing to you, you’re not alone, but bear with us). Here are the data-proven reasons that foam packaging works so well:
Foam tensile strength is the amount of stretch or give the foam has before it breaks. Different foam packaging types offer different strengths depending on density, composition, structure, and the manufacturing process used to create it. Heavier products require different foam tensile strengths to ensure the appropriate strength and give is available for the ultimate packaging protection.
The cushioning curve is the math behind how strong certain foam packaging is compared to the weight of the product nestled within it. In layman’s terms, we’re trying to figure out: how high and fast can I drop or throw this package before the product inside is damaged? If we know that, then we know what conditions we need to ship these products and what specific combination of packaging material + thickness we need to choose to offer the best protection to the product.
The indentation load deflection (ILD) and indentation force deflection (IFD) are used interchangeably and measure how much force it takes to compress foam. Usually written like “10 pounds of pressure compresses foam at 25%”, this helps you determine what kind of foam and type you need to support the weight of your product.
When you combine tensile strength, cushioning curves, and ILD/IFD, you get a clear picture of how foam will perform in real-world conditions. Foam specs often also include details like density, elongation, tear strength, and air flow, along with minimum and maximum requirements, test properties, and measurement methods. Foam experts can help interpret these specs to match the right foam to your specific product.
In a recent case study with Montreal Assembly, we compared foam’s ship-in-own-container (SIOC) approach to the traditional box-in-a-box (BIB) method. Both methods protected the products effectively, but the results clearly favored foam. The SIOC design was faster to pack, lighter to ship, and slightly less expensive, while using significantly less material overall. Customers also had a smoother unboxing experience: one box, one reveal, minimal waste. Dollar for dollar, pound for pound, foam proved to be the smarter, more data-backed choice.
Curious to see the full breakdown? Read the complete case study.
Foam packaging is one of the best science-backed choices for shipping items, and it offers the ultimate data-driven protection. Each step of the foam packaging process takes into consideration the weight, type, and needs of your particular product while also saving you on costs and excess materials. The great thing about foam packaging is that it can be determined from every angle. It’s not simply a guess to protect your packaging—it’s science (and a little bit of math) to make sure your products are good to go everywhere they go.
Curious to see how foam compares to your current packaging?
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.