Effective Types of Foam Packaging that Make Your Product Transit Breakage Proof

types of foam packaging

How can you avoid the likelihood of your product being damaged during transit? The core question arises when you face the crisis of receiving a stream of products for replacement due to impact, uncontrollable vibration, and fluctuation in temperature. To bypass such issues, you need a customizable shield that absorbs all the shocks and protects your products with the ultimate cushioning effect.

Nothing is more effective in these scenarios than using foam packaging with traits to save breakable products, electronics components, and heat-sensitive pharmaceutical items to overcome logistics challenges. But foam packaging has various types based on foam materials, eco-friendliness, and budget. To determine which one is suitable for you, continue reading.

Types of Foam Packaging Materials

types of foam packaging materials

Expanded Polystyrene

Expanded polystyrene, also called a styrofoam sheet, is a rigid foam used as a packaging foam block. You can customize the shape and size according to the dimensions of your products or box. You can use this packaging foam for protecting lightweight appliances and other delicate products.

When it comes to budgeting, these foams provide the most cost-effective packaging solution. However, they are easily cracked due to high brittleness. This may be a concern to not prioritize it for heavy-weight items or bulk packaging.

Polyethylene (PE)

If you need stronger shock absorber foam packaging, use polyethylene, as it’s harder and denser compared to other foam blocks. They provide high durability and vibration-damping effects that make them ideal for getting more stability while shipping fragile items, heavy machine parts, large speakers or amplifiers, and heavy cables. Moreover, pharmaceutical brands use PE foam to pack sensitive medical devices to eliminate the risk of damage due to chemicals and atmospheric moisture.

Polyurethane (PU)

Polyurethane is typically used as sponge packing inserts. Whether you need soft packing foam or hard one in multiple colors and shapes, PU will meet your requirements to keep your products safe from even the slightest scratches. How? Foam packaging suppliers change polyurethane's stiffness by transforming the foam material's density during production. Also, it will minimize the chances of rolling out objects inside the packaging.

Companies are advised to use these foam packaging for the shipping of electronics, glassware, hard drives, cameras, lenses, lights, and other sensitive components.

Crosslinked Polyethylene (XLPE)

Cross-linked polyethylene foam packaging material is used for the safety of class-A products, including medical or military equipment. The foam packaging acquires more stiffness and chemical resistance because of its peculiar structure with crosslinking. Compared to polyethylene, XLPE is more expensive and stiff, providing an abrasive-resistant surface and thermal insulation.

These inserts' colors, shapes, sizes, and thicknesses are completely modifiable, so pick the packaging foam that aligns with your valuable product needs.

Anti-Static Foam

Accumulation of charge on your electronics products can ignite a fire. Anti-static packaging foam has the feature of releasing all the electrical charge arising on the product packaging safely and slowly. In the long run, anti-static foam is a cost-effective solution because your reactive electrical products will remain harmless from static charge, eliminating the chances of return and damaged products.

Bonus: You can also use other types of packaging foam available from packaging suppliers

  • Ethafoam

  • Neoprene Foam

  • Silicone Foam

  • Bio-Based Foam

Different Styles of Foam for Packaging

different styles of foam for packaging

Foam Wrapping Roll

Foam wrapping rolls can be made of various materials like styrofoam. You will have a continuous sheet of foam packaging to grab and wrap around your product to make it abrasion-resistant. Also, you can use foam wrapping roll pieces and put them inside the product packaging to fill voids and offer a gentle cushion.

Foam Sheet

The main difference between foam wrapping and foam sheets is that the former can be cut and torn apart, but the foam sheet can’t. You can vary the thickness of the foam sheet and obtain the perfect dimension for wrapping collectibles, frames, small electronic devices, and glassware. Moreover, most brands prefer to use foam sheets for packing because of their characteristics:

  • Easy-to-use

  • Effortless grabbing

  • Handy padding sheets

Foam Pouch

Foam pouches are lightweight, thin packing bags that hold your fragile products and protect them during bumping in the shipping process. These bags are available in all sizes, whether you need large or small foam pouches. The best thing about foam pouches is that they are convenient to use. You just need to put your products inside the pouch and seal them entirely.

Foam Tubing

When your product has a distinctive shape and is longer than usual, you need to protect the whole length with foam packaging. The variant shape will never allow you to use foam wrapping because the void will never be filled properly. Here comes the foam tubing; never scruff the exterior/surface of your products, as they are soft-packing foams.

Foam Blocks

Foam blocks are made of closed-cell polyethylene and come in different standard sizes, including:

  • 300mm x 200mm for smaller items

  • 600mm x 600mm for larger items

Whatever the size of your product, request your foam packing supplier to deliver the dimensions you need.

Foam Liners

Foam liners are also called egg crate foam because they resemble egg cartons. The lifted shapes on the surface are lined with the packaging boxes and get compressed to any sort of impact. They abort all the forces of blow and leave the product unharmed. You can use these foam block packaging for cartons and lining boxes.

Pick and Pull Grid

Pick-and-pull grid foam packaging is cut into smaller sizes but fits into the same larger foam sheet. They are highly versatile when it comes to changing the shape of these inserts. They typically have a half to 1-inch grid formation. You just need to pull some grids to create a space for placing your square or rectangular products inside.

Further Reading: 4 Creative Uses of Small Gift Boxes to Promote Your Business

Decision-Making Parameters for Choosing the Right Packaging Foam Type

choosing the right packaging foam type

The Weight and Size of Your Product:

If you plan to transport your multiple products in the same packaging, consider the size and weight of your items. After all, using foam packaging with the required stiffness, softness, and durability is important to endure the product's weight.

Importance of Static Charge:

Go with anti-static foam when your products are electronics. The foam will neutralize the surface of the instrument so there will be no chance of a spark on it.

Require safety from Moisture:

In the case of perishable products, moisture, and heat can cause the spillage of items. Using foam packaging will extend the life of your perishable product even on the retail shelf.

Different Foams for Base and Lid:

Some products have very fragile surfaces, so use a lid made of PE for more stiffness and protection, while different foam packaging bases bring cost-effectiveness.

Read Our Client Success Story: Bath Nutts Farmhouse Finding Success with Custom Window Die-Cut Boxes


The significance of effective foam packaging cannot be denied, especially when it comes to resolving logistics challenges and guaranteeing product safety. Each material, from polystyrene to crosslinked polyethylene, brings exceptional benefits for protecting fragile electronics or heat-sensitive pharmaceuticals. The diversity in foam styles also ensures versatility in addressing every packaging demand. Investing in quality-made and most suitable foam packaging is paramount for securing fragile, perishable, and heat-sensitive products during transit.

Half Price Packaging has the technology and expertise to meet all clients' demands. Our custom boxes feature all the functional, cost-effective, and stylish features to make your product outshine the competition. Whether you need packaging with soft or stiff foam as inserts, contact us to get an instant quote.

Start your Packaging journey with Half Price Packaging

Get in touch with our product specialist now.

Begin Your Journey

Order a Sample Kit

Get Free Consultation and Order Your Sample Kit to feel More Confident for Choosing Half Price Packaging as your product packaging partner.

sample kit image