The type of packaging you choose matters. Higher-quality packaging foam keeps your products safe during shipping and storage. But how is foam for packaging made? With years of experience in the field, our experts at Foam Industries have all the infoamation.
Keep reading to learn about the different foam types and benefits, the manufacturing process, and how foam packaging is made (AKA the fabrication process).
Packaging Foam Types and Benefits
Before getting into the exciting foam packaging manufacturing process, it’s important to understand how the various types are used and learn how foam is made.
Related Content: What Kind of Foam is Used for Packaging?
Polyethylene (PE) Foam
- Highly popular, low-cost foam
- Chemical- and water-resistant
- Industrially recyclable materials
Polyurethane (PU) Foam
- Soft, plush feel
- Flexible foam packaging
- Elegant aesthetic
Cross-Linked Polyethylene (XLPE) Foam
- Extremely durable
- Chemical- and heat-resistant
- Won’t scratch painted surfaces
Expanded Polyethylene/Expanded Polypropylene (EPE/EPP) Foam
- Flexible yet firm foam
- Sturdy enough for stacking
- Won’t scratch painted surfaces
Expanded Polystyrene/Extruded Polystyrene Insulation (EPS/XPS) Foam
- Most affordable foam
- Perfect for light cushioning needs
- Great insulative properties
How Foam Packaging Is Made: The Manufacturing Process
Now that you have an understanding of the different foam types, it’s time to answer the question, how is foam packaging made? To answer this question, we’re going to explain the manufacturing process and the fabrication process.
In the manufacturing process, the foam itself is created. We source some of our foams from our friends at Pregis, who are world-class at making the foam-tastic materials we use every day.
Each foam type has various complexities during the manufacturing process that involve a lot of chemistry and technical terms, so we’re opting for a simplified version to help your understanding. In the most basic form, the foam-making process involves blowing gas bubbles into plastic by mixing and pressurizing the components at specific temperatures until they reach the desired density.
By the time everything cools, it looks just like the foam you know and love. After that comes our fabrication process.
How Is Foam Packaging Made: The Fabrication Process
Foam packaging is fabricated in several different ways depending on what it’s used for. The list below features our most popular foam manufacturing methods and how they are used to create our specialized packaging.
5-Axis Waterjet Cutting
The 5-axis waterjet system is an ultra-cool robotic water blaster that cuts at angles up to 60 degrees. Using an extremely high-pressure, focused stream of water (never test this with your limbs), it carves the foam into the final shape.
Watch it in action:
Die-Cutting
Foam die-cutting machines are an industrial-sized version of a traditional craft cutter. Think bigger, better, and with more advanced digital hardware. But instead of cutting out paper, the machine cuts our foam into intricate and project-specific shapes.
CNC Router
A computer numerical control (CNC) router uses a rotary tool that moves side to side and up and down to cut a design into Foam Industries’ projects. Imagine it as a paper cutter both on the vertical and horizontal parts of a machine, like a graph with an X and Y axis.
Flash-Cutting
Flash-cutting is a highly efficient CNC machine that cuts shapes into foam with a knife-like tool rather than a die. The software is pre-programmed with a design to determine in which direction the knife goes to replicate the programmed shape on a slab of foam.
Vertical and Horizontal Contour Cutters
Vertical and horizontal contour cutters are another type of CNC machine that removes parts of the foam as needed. Using high-powered suction capabilities, the machine also stacks foam and keeps it stable.
Hot Plate Laminators
Once heated, foam melts. So, hot plate lamination uses this property to adhere foam together or to other materials. The foam is pressed onto the hot plate to melt one side of the foam just enough to create an adhesive bond to another piece of foam. A bit of pressure is applied and, voila! You now have a single stack of foam. It’s like when you lick a foam peanut and stick it to another foam peanut—except permanent.
Roll Skivers or Roll Splitter
For extra dense foam, roll skiving, or roll splitting, is necessary. The roll skiving machine compresses the foam with steel rollers, feeding it through the machine before using a self-sharpening blade to slice through the foam to whatever thickness is needed.
PSA Laminators
Using PSA (pressure-sensitive adhesive) lamination, or adhesive lamination, uses PSA binding agents applied onto the foam. Once the adhesive is applied, pressure is applied, and the cutting tools we mentioned above can then be used on large pieces of foam rather than sheets.
Convoluters
The patterned convoluted foam is made using a special roller tool. Known as a convoluter, this powerful tool combines the techniques of a roll splitter and die cutter. Foam is fed through the machine where it’s squashed into the specified shape using a lot of pressure and the roller’s momentum.
What Can You Do with Foam Packaging?
After learning how foam packaging is made, you might be curious about what you can do with it. Here at Foam Industries, we form the perfect packaging for numerous products to protect them during shipping or in the client’s own home. Our packaging is used for protecting products during transit by cradling the product with a custom design. By using our packaging, you can experience these benefits:
- Reduce shipping costs
- Keep products clean
- Ensure products ship safely
- Eliminate damaged equipment
- Protect against bumps and falls
Related Content: 3 Reasons to Use Foam Packaging
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. Do you want to work with us to package and protect your products during shipping and more?
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.
