In the shipping world, there are so many packaging options to choose from, so it’s easy to get overwhelmed fast. Especially when it comes to choosing between corrugated packaging and foam packaging. Both have their benefits and work well in certain situations, but it can be hard to make the right selection if you don’t have a clear understanding of both.
In this article, we’ll explore both corrugated and foam packaging: what’s the difference between the two, and which is best for your application?
What is Corrugated Packaging?
Corrugated packaging is most commonly built from cardboard. What makes packaging corrugated is the structure: flat layers of cardboard that sandwich layers of wavy flutes in between. These flutes create a shape that looks like a honeycomb when viewed from the side.
For stronger packaging, the number of flutes can be doubled or even tripled. Decreasing the space between flutes can also increase the strength of the corrugated packaging.
Corrugated Packaging Uses
Corrugated cardboard packaging is a good option for small and lightweight products. For example, small electronics like smartphones and wireless Bluetooth earbuds often use corrugated packaging for both their case inserts as well as void fill for a box-in-a-box shipping method. These very small products can be safely supported by corrugated packaging, which provides enough support at a reasonable price.
Corrugated packaging is also sufficient for other products that are lightweight and not easily damaged. Many other consumer goods like books, toys, pharmaceuticals, and board games rely on corrugated packaging for shipping.
What is Foam Packaging?
Foam packaging is a lightweight, durable material used to add cushion and prevent damage during shipping and delivery. There are numerous foam packaging types to choose from that result in a harder, more durable foam or a softer, more pliant foam. The type of foam you select is highly dependent on the product you’re trying to ship, but there is a variety to choose from for almost any product shipment. Foam packaging offers highly shock absorbent options that make it great for fragile products and insulated options for shipping fresh or frozen food. Overall, foam packaging is a fantastic choice for maintaining low shipping weights, offering advanced protection for fragile products, and offering insulation as needed.
Foam packaging can also be customized much more than corrugated packaging. Depending on your need, there are custom inserts, sheets, blocks and liners. Explore the different types of foam packaging on our blog: How to Choose the Right Foam Packaging Type
Foam Packaging Uses
Foam is a bit more versatile than corrugated packaging. For that reason, foam is a great option for a few use cases:
- Cushioning heavy and/or large items
- Supporting fragile products with sensitive electrical components
- Insulating temperature-sensitive items and keeping moisture out
These use cases aren’t mutually exclusive, but represent the most common categories of product protection needs.
Related Content: Explore Sample Foam Packaging Applications
What’s the Difference Between Corrugated and Foam Packaging?
The materials used in corrugated boxes and foam packaging are the biggest differences, but there are a few major comparisons in how they are each used to note outside of that.
Data-Backed Structure
When it comes to the capabilities of each structure, the strength of foam is backed by data whereas corrugated packaging uses a lot of guesswork.
Cushion drop testing determines the amount of shock absorption in foam. The science behind it involves a basic math equation to determine the weight of your object nestled within the foam. From there, simple physics shows how much foam is needed to protect a product within certain drop distances (such as being lifted with a set of hands). All of this can be determined to figure out the precise amount of foam needed so nothing is wasted and extra money isn’t spent on packaging.
Related Blog: What is a Cushioning Curve?
For corrugated cardboard packaging, it’s harder to apply science and physics in the same way. Put simply, cardboard packaging simply doesn’t offer the same cushioning as foam. It offers block and brace protection only. Oftentimes, boxes work best for products that aren’t breakable, don’t need the extra foam protection, and can be left loose in a box during shipping and delivery.
Case Study: Ship in Own Container vs. Box in a Box
If the data-backed structure and shock absorption are your end goals, foam is your best option all the way. For lightweight shipments that don’t require cushioning, corrugated boxes are a perfectly adequate shipping option.
Support for Heavy Items
When trying to ship heavier, more fragile, and expensive items, foam is your best option for shock absorption and to add protection from damage during transit. On the flip side, lightweight items may not require foam because corrugated packing will suffice. Heavier parts can easily break, tear and rip through corrugated packaging in transit.
When sending products that are both heavy and fragile parts like windshields or scratchable surfaces like external automotive parts, foam can also be a great option. Foam packaging protects the product in transit without scratching.
Related Blog: Foam Packaging Applications for the Automotive Industry
Both are Sustainable
For sustainability, you might think that corrugated cardboard is the best option because it's made with paper while foam uses plastic, but foam can be surprisingly sustainable depending on your selection. Certain types of foam packaging can be recycled or upcycled. XLPE foam in particular is 100% circular—none of it gets incinerated or sent to landfills.
It’s also important to note the environmental impact when you choose the wrong packaging type and need to ship and deliver again because the product broke upon arrival. Once you consider the extra gas, time, packaging, and product creation needed to ship and deliver a second or even third time, it would have been better if you used a less sustainable material in the first place and your item arrived intact to reduce the environmental impact both short term and in the long run.
Related Read: Sustainability Packaging
Another sustainability point to touch on is that foam can be reusable in ways that cardboard can’t. The fact of the matter is that corrugated cardboard packaging can’t hold up to moisture well, it won’t maintain its shape for long with heavy use, and it breaks down over time. On the other hand, foam packaging can be reused time and again if you plan accordingly. It protects products better, for longer periods.
Case Study: Reusable Tote for Aerospace Client
Is Corrugated or Foam Packaging Better?
Both corrugated cardboard packaging and foam packaging are great for shipping and delivery depending on your needs. It’s hard to say whether corrugated or foam packaging is better because they are great for different use cases.
Corrugated packaging works perfectly well for lightweight products or items that aren’t as breakable. Foam packaging is a fantastic option for more fragile, heavier items that need more shock absorption and protection during transit. Foam is also the better choice for products that need to retain a temperature and/or need to resist moisture.
Corrugated packaging and foam packaging can also be a great option in tandem to prevent movement during shipping. Focusing on a tight fit by protecting the edges of products or completely encompassing the item in foam is a great way to protect a product from jostling.
Find Your Best Option with a Packaging Expert
Choosing the right packaging the first time can greatly reduce shipping damages. If you’re hoping to improve the quality of your automotive shipments, Foam Industries can help.
Foam Industries is a leader in the packaging industry and 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.
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.
