An explanation of what Plastazote® is
How can it have benefits for your packaging and supply chain
You may have heard the term “Plastazote® foam” before; you may not.
You may be aware of the benefits of foam packaging and how it can cushion your products or equipment from knocks, impacts, and vibration during transit, or you may not.
One thing you will almost certainly be aware of is the issues your business could face if it consistently supplies damaged products or parts to customers, or if equipment arrives on site damaged and unusable.
And if not, you really should.
The costs to your business can be high. Returned products, written off stock, unproductive staff, project delays, upset customers, poor brand perception, and more can all result from transit damage.
So are foam inserts the answer? If so, what is Plastazote®, and should you use it for your protective packaging?
Contents
- What is Plastazote® foam?
- How is it manufactured?
- The key benefits of Plastazote® foam
- Applications for Plastazote® foam
- Protective case foam inserts
- Shadow foam/tool control inserts
- Cushion packaging
- Foam dunnage
- Line-side packaging
- Electronics packaging
- Military packaging
- Medical packaging
- Archive packaging
- Other uses
- Summary
What is Plastazote® foam?
Industry standard closed-cell foam
Plastazote® is a brand name for a specific type of foam that has quickly become the industry standard for high-performance foam packaging.
Manufactured by Zotefoams® and part of a larger range of foams (the “AZOTE® family”), it is effectively a closed-cell, cross-linked foam that offers a wealth of benefits and can be easily converted and fabricated into foam packaging.
The foam consists of numerous nitrogen cells held within a polyethene material.
It is called “closed-cell foam” because the nitrogen cells are not open/connected like a sponge. This also means gases and liquids are not readily absorbed by the material.
In fact, this is one of the many benefits of the material.
It is lightweight, completely odourless (as it doesn’t absorb water), buoyant, non-toxic, and, being made of polyethene, has exceptional chemical resistance to most oils, solvents, acids, and alkalis.
Additionally, it is weatherproof, highly UV-stable, durable, and relatively easy to wash, disinfect, and wipe clean.
However, arguably its most important property is its ability to recover from repeated impacts, as it is highly energy-absorbing (which also makes it a good thermal insulator). In effect, each cell acts like a balloon, enabling the foam to bounce back to its original shape.
This is what makes it so suitable for foam inserts for cases and foam packaging in general.
How is it manufactured?
Manufacturing process for Plastazote® foam
Whilst the material itself is manufactured in a process whereby nitrogen is “blown” into the polyethylene before expanding, perhaps of more interest is the foam conversion processes that this material allows for.
Plastazote® foam can be easily shaped and cut. It can be routed cleanly on CNC machinery, split, sawn, die-cut, shaped with waterjet equipment, butt-welded, and even heat-laminated.
As such, the material can also be bonded to other materials, including fabrics, wood, plastics, and metals (making it ideal to fix into cases as inserts).
Finally, the cross-linking of the foam makes it easy to mould at low temperatures, either by compression or vacuum moulding. Because polyethylene has a low softening temperature, the foam forms easily without excessive heat.
All of this means there are numerous ways to create highly detailed profiles, enabling fragile or high-value items to have bespoke levels of protection engineered into the foam.
This can actually be taken a step further, with a little-known (or underused) piece of software that allows for exact levels of protection to be created based on theoretical compression testing and real-life drop test data.
This can effectively eliminate transit damage, making Plastazote® the material of choice for high-protection packaging applications.
The key benefits of Plastazote® foam
Summary of the advantages of using this foam material
The list of benefits associated with Plastazote® is extensive and varied. However, here is a summary of the key features that make Plastazote such a versatile packaging material:
- Lightweight and durable
- Good impact absorbing properties
- Good surface protection characteristics
- Consistent with regular cell size
- Wide range of densities and colours
- Water repellent and buoyant
- Excellent chemical resistance
- Good thermal insulation
- Range of high-performance options
- Non-toxic and safe for handling
- Easy to work and shape
- Non-staining
- Extremely low odour
Applications for Plastazote® foam
Main uses for closed-cell foams
It is all very well to highlight how versatile and high-performance a material is, but unless it has real-world applications that deliver tangible benefits for your business, it is pretty meaningless.
Fortunately, Plastazote® is popular for more than its credentials and is widely used across a range of applications, including packaging and transit.
If your business uses any of the following packaging or handling methods in your day-to-day operations, you could make significant improvements by utilising Plastazote®.
- Case inserts
- Tool control
- Cushion packaging
- Tote inserts/pads/fitments
- Cradles/dunnage/line-side
- Electronics packaging
- Military packaging/explosives
- Medical packaging
- Retail packaging
- Archival packaging
Protective case foam inserts
Allowing for precise levels of protection
Perhaps the most widespread use of Plastazote® (at least in the packaging market) is as foam inserts for cases.
There are several reasons for this.
Firstly, as mentioned above, Plastazote® foam can be manufactured to provide specific cushioning performance from shock, impact, and general mishandling. This means that when coupled with a suitable protective case, high-value products, tools, equipment, or components can receive the highest level of transit protection.
Additionally, the ability to create detailed recesses and profiles within the foam helps hold items in the case during transit.
This not only keeps them organised but also ensures they do not damage each other during movement.
Finally, the foam, being low-odour and available in a range of colours, is useful for presentation and branding.
As a result, Plastazote® is used in a wide range of presentation and sample cases to enhance their aesthetic appeal during important sales pitches and presentations.
Shadow foam and tool control inserts
Improve organisation and prevent equipment loss
Another common use for Plastazote is as tool-control foam.
In fact, this is critical for industries such as aerospace, medical, and automotive.
By laminating different-coloured, contrasting foams and creating recesses for tools, this “shadow foam” quickly and clearly indicates whether a tool has been returned to the case.
Although initially developed to save lives (e.g., ensuring tools were not left within aircraft engines or even in patients’ bodies), it also offers benefits for other applications.
Leaving tools on site (effectively losing them) can cost companies thousands each year. It can also reduce productivity if field engineers arrive on site without the correct tools or equipment.
Tool control foam quickly highlights when a tool is missing, enabling appropriate action.
Cushion packaging
High-performance protection
Similar to case inserts, Plastazote® is widely used for “cushion packaging”.
As the foam can be moulded or machined to exact shapes, it can hold items in place (preventing movement during transit) whilst also absorbing vibration and impact energy.
Additionally, many grades offer a soft surface that can protect the products transported within the foam (for example, highly polished or painted parts and components).
Foam dunnage
Inserts, pads, and fitments for totes (dunnage)
Returnable packaging is another area where the use of Plastazote® is surprisingly widespread.
It is usually used for two reasons in such applications.
First, the foam can be manufactured to securely hold parts, components, or even fish products in place within the outer tote. Whilst not fully encompassing the part as with case inserts, it nonetheless prevents the items from moving during transit and from damaging each other.
Secondly, by separating the items and isolating them from the inner walls of the containers (and from each other), any specialist surfaces (again, polished or painted) are protected.
The durability of the Plastazote® material also ties in with the “multi-use” requirements of the returnable packaging.
Line-side packaging
Cradles and dunnage for handling operations
Plastazote® is suitable for your supply chain packaging, in-plant handling, and line-side packaging. This is particularly popular in the automotive industry.
Working much like multi-trip packaging, Plastazote® cradles or dividers (often referred to as foam dunnage) protect items moving through your factory or production facility from mishandling, surface scratches, and scuffs.
Another benefit is that separating parts or components can reduce assembly or picking times, as operatives can easily retrieve items from the tote and can more easily judge the remaining stock in a particular container.
Electronics packaging
Anti-static and ESD-safe foam grades
If you are manufacturing, handling, or shipping static-sensitive devices (microchips, circuit boards, or finished products that incorporate electronics), they can be susceptible to electrostatic discharge (ESD).
This atmospheric static can irreparably damage these items during storage and transit. However, there are grades of Plastazote® that can conduct or dissipate these charges, effectively protecting the items within.
Plastazote® is widely used in electronics packaging.
Military packaging
Foam approved for munitions and explosives packaging
There is a variety of criteria for military packaging, and whilst many involve the use of Plastazote® foam to protect sensitive items, there are specific applications as well.
For example, there are grades of Plastazote® foam that are approved for military equipment, as well as flame-retardant grades. These are manufactured and tested to the relevant defence standards, similar to waterproof cases from Peli and SKB.
Medical packaging
Plus other healthcare applications
There are a number of uses for Plastazote® foam in the medical market.
For example, specific grades can tolerate irradiation sterilisation, whilst others can also withstand heat sterilisation.
This makes them widely used for transporting implants, surgical instruments, and even mobile medical devices, which may also require static protection.
Archive packaging
Safe long-term storage
Finally, because of its purity, stability, and inertness, Plastazote® is widely used for archival storage.
With added properties of low odour, low VOC, non-support for microbial growth, and non-staining, Plastazote® can be successfully used for the storage and conservation of artefacts, works of art, and other historical or antique items.
Other uses
Even more uses for Plastazote®
Whilst this guide covers the use of Plastazote® for packaging and storage applications, the material is so versatile that it is used in numerous other applications.
These include use in sports equipment (padding, mats, etc.), artificial limbs, insoles for shoes, gaskets and seals for industrial applications, construction applications, and even set designs and props in live performances.
It is this versatility that makes Plastazote® foam so popular.
Summary
Take advantage of Plastazote® foam inserts and packaging
So, should you use Plastazote® foam for your packaging or handling applications?
The likely answer is yes if you are experiencing returns or damaged products, either during transit or during handling in the plant, or have high-value items that need to be protected.
Whether used for case inserts, foam dunnage, or protective packaging, Plastazote® can make a surprisingly significant impact on your business.
Please note: AZOTE®, Plastazote®, and Zotefoams® are registered trademarks of Zotefoams plc.
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About the author
Initially joining GWP Protective back in 2004, Richard’s vast, specialist knowledge and experience mean he now heads up the business as General Manager.
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