Foam conversion specialists
Whether you already use protective packaging or are looking at a new project for your business, choosing the right foam converters is vital.
Foam converters use a range of materials, including Plastazote, Stratocell and Ethafoam, and convert them into various products. While this includes everything from gaskets to sports equipment, most foam converters focus on manufacturing protective packaging. Foam conversion processes typically employed include die cutting, CNC routing, and laser cutting.
At GWP, we have been among the UK’s largest foam converters for over 30 years. Our team of experienced designers and an extensive range of modern conversion equipment allow us to make foam inserts and packaging of the highest quality. We can even calculate the precise amount of material needed to protect specific items from damage and supply your outer protective cases or corrugated packaging.
Foam packaging converter
Foam packaging and inserts to protect or present any product, component, or equipment.
Foam inserts (for cases)
High-performance foam inserts for cases, tailored precisely to your products, provide exact levels of cushioning protection.
Foam packaging
Foam packaging and end caps are perfect for shipping high volumes of valuable items, being cost-effective and preventing transit damage.
Foam dunnage
Returnable packaging solution that protects parts and components, including decorative surfaces, throughout your supply chain.
Luxury foam packaging
High quality finishes and aesthetics perfect for retail applications and adding value to luxury product packaging.
Recycled foam
A range of eco-friendly, recycled foam materials that improve sustainability and avoid the Plastic Packaging tax.
Anti-static foam
Specialist conductive foams that help protect electronics and static-sensitive items from damage caused by ESD.
Popular engineered foam packaging
Businesses and professionals primarily use custom foam inserts within protective cases. Our foam inserts for cases are precisely tailored to be a perfect fit for your products and your chosen case or container.
Foam converter FAQs
What is foam conversion?
Foam conversion refers to turning a raw foam material into a useful product. While this can be for anything from upholstery to shoe insoles, the term foam conversion generally applies to the manufacture of protective packaging such as box or case inserts.
What methods do foam converters use?
Several methods of foam conversion exist, including die cutting, CNC routing, waterjet cutting, and even laser cutting/engraving. For many protective packaging products, several of these processes are used together to create the finished item.
What types of foam do converters use for packaging?
Converters use different foams to create various forms of protective packaging. However, the most commonly used (and versatile) are polyethylenes such as Plastazote®. This material is widely used in a range of products, including high-performance case inserts. Other foams, such as Stratocell and Ethafoam, are used for high-volume/single-trip packaging requirements, such as foam end caps.
Is there a difference between case foam and packaging foam?
As a general rule of thumb, Plastazote® is suited to foam inserts for protective cases and other applications such as tool control and shadow boards. Lower-cost foams such as Stratocell are popular for foam “packaging”. This is because Plastazote® has a longer life, whereas Stratocell is cheaper and more suited to single-trip applications.
What is Plastazote®?
Plastazote® is an extremely versatile cross-linked, closed-cell polyethylene foam. It is manufactured by Zotefoam® (and is part of the AZOTE® polyolefin foam range of products) and is used for products as diverse as swimming floats, sports equipment, gaskets, and—of course—protective packaging.
Does foam absorb water or moisture?
The foams used in case inserts and other forms of packaging are known as “closed cell.” This means that cells are completely encased in the polyethylene material, meaning that water or other liquids cannot be absorbed into the material.
Is packaging foam different from upholstery and mattress foam?
While there are some similarities between the foams used for packaging and upholstery, the main difference is that those used in furniture are open-celled. This means they are generally cheaper and also more comfortable. However, they would not typically be as effective in protecting items during transit as closed-cell foams.
How do I choose a foam conversion process for my packaging?
The choice of conversion methods, not to mention material types, grades, and colours, can be overwhelming. This is why it is essential to work with an experienced foam converter. Doing so allows you to leave the technical aspects of any design you require to professional, knowledgeable engineers.
UK foam converters
Many companies offer foam fabrication and conversion services. For many, this is simply a way to sell more exterior cases or boxes, with little thought to how the foam insert can impact the longevity and success of the packaging.
However, with over 30 years of experience, at GWP Protective we take a different approach to foam conversion and design projects.
In fact, we always ensure that by working with us, your business sees a direct, positive impact on your operations. This is true whether you are looking for high volumes or a one-off design and if you are looking for a precisely engineered level of cushioning protection for high-value items or need to ship large numbers of consumer goods.
Expert foam conversion services
With a depth of understanding and knowledge as polyethylene foam converters, your business can tap into a wealth of experience in converting Plastazote®, Stratocell and Ethafoam materials (amongst others).
A team of expert advisers can guide you through the entire foam design and manufacturing process, ensuring your foam packaging is produced to your exact requirements.
And, unlike many other foam converters, this covers everything from transit protection to the presentation of luxury consumer goods, and everything in between.
This level of knowledge and support—your business will have a dedicated advisor and designer allocated to you—is enhanced further using the latest technology. This includes state-of-the-art CAD design software used by a dedicated, highly skilled foam design team.
So, if you are looking for successful, experienced foam converters, GWP Protective can help.
If you would like free, no-obligation advice on the best form of foam packaging and/or inserts for your business, please speak with one of our friendly and knowledgeable foam converters today.
Please note: AZOTE, Plastazote, and Zotefoams are registered trademarks of Zotefoams plc.
All foam options
Protective cases
Other outer packaging
Related guides
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01722 416 440
Mon – Fri 08.30 – 17.00
protective@gwp.co.uk
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