When choosing a foam for your packaging application, we often get the question: Which one is the best?
“Best” is subjective, of course, and it also depends on your specific application. However, there’s always an answer. Today, our team at Foam Industries will compare the three most popular types of foam used in packaging – XPLE, PE, and EPE – and answer the question: which one is the best choice.
Cross–Linked Polyethylene (XLPE) Foam is the marriage of unparalleled durability and unlimited aesthetics. It’s essentially a more magnified version of polyethylene foam (PE) and is specially made to be “cross-linked,” meaning that there’s extra-strength foam bonding that leads to high resistance, strength, and durability. Essentially, XLPE foam is the Hulk-ified version of regular polyethylene foam. XLPE is extremely durable and rigid to keep merchandise safe, yet doesn’t scratch painted surfaces. While it has a variety of applications, it’s extremely well-suited for influencer kits and other marketing materials where safe delivery, the unboxing experience, and display are all critical.
► Related Content: Benefits of Cross–Linked Polyethylene Foam in Packaging
Polyethylene (PE) Foam is low cost, resilient to chemicals and water, and industrially recyclable. It’s suited for a wide variety of applications – end caps, case inserts, and other common types of packaging. By melting plastic and adding gas bubbles to the mixture, it results in a cushion-like foam that’s both soft and protective.
► Related Content: Benefits of Polyethylene Foam in Packaging
Expanded Polyethylene (EPE) Foam is ideal for applications where flexibility in design but rigidity in form is crucial. EPE foam starts as a bunch of plastic beads, becomes heated up, and is combined with air to form a lightweight foam. The air bubbles help the dense plastic to become lighter and create cushioning by forming a soft, sponge-like material. This can be used in various industries for packaging or creating goods.
► Related Content: Benefits of Expanded Polyethylene Foam in Packaging
With so many foam types, it can be overwhelming to determine what works best for your project, but we’re here to make it easier. Compare cost, performance, moisture resistance, strength, insulative, and environmental impact below for cross-linked polyethylene, polyethylene, and expanded polyethylene foam.
| Foam Type | XPLE | PE | EPE |
| Cost | High | Very Low | Low |
| Durability | High | Medium | Low |
| Color Options | Many | Many | Many |
| Recyclability | None | Recyclable | Limited |
Which type of foam is the best for packaging? This is the question we get the most, and it’s the hardest to answer generally because it depends on what your product is, your budget, how it will be shipped, if it will be displayed after, etc.
At Foam Industries, we love all foam – but there’s a correct foam to use for every given packaging scenario. Heavier or more fragile shipments are going to have the safest journey cushioned by XLPE foam while delicate or high-density shipments are going to want to snuggle up in EPE or PE foam. EPE or XLPE foam are best for insulating. PE is the cheapest while XLPE is the strongest. When deciding which foam to use, keep your product in mind.
However, for a vast majority of applications, our recommendation is usually Polyethylene (PE) Foam for a couple of reasons:
► Related Content: How to Choose the Right Foam for Your Custom Case Insert
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.
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.