Foam Converters

GWP Protective have over 25 years’ experience as independent, UK based foam converters.

This means that regardless of the industry or market sector you operate in or the products, tools, or equipment you need to protect, your business can source custom size foam inserts and bespoke foam packaging that you can truly rely on.

Please select from the categories below to see all types of foam insert, packaging, and options available from GWP Protective. Alternatively, if you cannot see exactly what you require, please contact a member of our team who will be happy to advise on the best solution for your specific application.

Please see below for the range of Plastazote® polyethylene foam inserts for cases / containers that GWP can design and manufacture for your business.

Low cost packaging foam such as Stratocell and Ethafoam end caps are ideal for minimising shipping damage and costs. Please see your options below.

Foam can often be overlooked for luxury packaging applications, but it’s a great choice for added value, brand differentiation and enhancing customer experience.

Besides packaging applications, foam dunnage can also help to dramatically improve the efficiency of part and component handling in production environments / assembly lines.

As well as being among the top UK foam converters, GWP are also market leaders in the design and manufacture of ESD safe / anti-static packaging, including a range of foam options.

Besides being leading foam manufacturers, as an independent business GWP Protective can also provide your business with the widest range of protective case options from a single supplier (and offer truly impartial advice as a result). See the case options you can choose from below.

Besides protective cases, you can also source your corrugated cardboard boxes, plastic totes, and anti-static packaging from a single source. And by doing so, your business can see improved compatibility (and therefore performance / cost effectiveness) between outer packaging and your foam cut to size.

Primarily utilising Plastazote® (for high protection applications), Stratocell and Ethafoam (for single trip requirements) plus a range of other specialist foams, GWP fabricate your foam inserts and packaging using a wide range of techniques. Many of these utilise cutting edge processes and CAD CAM technologies.

This variety of techniques employed ensures that your case inserts and / or foam packaging is tailored to your exact requirements, whilst maintaining the performance levels demanded by the your specific market, application or product.

Please continue reading below for further information on the specific types of conversion and technical foam services GWP Protective offers.

In essence, die cutting is the process of using a tool (die) to press foam to specific shapes, creating bespoke cushion packaging and case inserts (it is also used for non packaging products such as upholstery foam).

Whilst it may sound simple, the process is so precise it can be used to cut through single layers of material (for example where different coloured foams have been bonded together in layers). This in turn allows for the creation of visually attractive results and precise finishes. This is known as “Kiss Cutting”, and is a process widely used by foam converters.

Die cutting as part of the foam conversion process is carried out on a flatbed press. The requirement for tooling however means that it is generally used for larger runs, where the cost of this tooling is more easily absorbed.

As expert foam suppliers, GWP Protective use the latest Die Cutting equipment at our production facility in Salisbury. This ensures your finished die cut foam products are produced to exceptionally high standards.

One of the main foam conversion processes used for the creation of case inserts at GWP Protective (and indeed many other foam converters) is CNC routing.

This is a computer-controlled process which is linked directly to our designers’ CAD software.

By uploading the 3-dimensional profiles to the machine, the router head is then able to systematically cut away foam material to create exceptionally intricate shapes within your fabricated foam products, to exacting tolerances.

By first digitising the product to be placed within the routed foam insert, GWP also ensures that the match between the item and the case insert is as close as possible.

CNC routing produces consistent, high quality engineered foam products. Also, due to the elimination of physical tooling costs (unlike die-cutting), the process can create one-off routed foam inserts very cost effectively.

As an alternative to CNC routing and Die Cutting, GWP Protective can also offer you engineered foam items that have been created by water jet cutting.

This equipment effectively uses a CNC controlled jet of water at high pressure to cut intricate shapes in foam materials

Water jet cutting has a number of advantages over traditional die cut foam and routed foam inserts. For example, it leaves no radius in corners, is exceptionally precise and does not cause heat build-up which can affect the properties of the foam.

Besides this, it can also create narrow slots to much greater depths than other methods, and provides a very clean, smooth finish with no dust residues either. It can also boast accuracy of up to 0.005″ (0.13 mm), and repeatability of 0.001″ (0.025 mm).

Besides this, fabrication of foam in this manner produces no hazardous waste, eliminates airborne dust particles and fumes, and uses very little water due to its’ “closed loop” setup.

Besides the details of the manufacturing processes used when producing your foam inserts and / or packaging as per the info above, you can also watch this short video to see them in practice.

Below is a list of the most commonly asked questions on the topic of foam conversion.

Can’t see the answer to your specific question? Don’t worry, a member of the GWP Protective team will be happy to help. Simply get in touch on 01722 416 440 or email
protective@gwp.co.uk.

There are many companies offering foam fabrication and conversion services. For many, this is simply a way to sell more exterior cases or boxes, with little thought as to how the foam insert can impact the longevity and success of the packaging.

However, with over 25 years’ experience, GWP Protective take a different approach to foam conversion / design projects.

In fact, we will always look to ensure that by working with GWP, 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. 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.

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 will be happy to 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 be allocated a dedicated advisor and designer – is enhanced further using the latest technology. This includes state of the art of 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.

Please note: AZOTE,  Plastazote, and Zotefoams are registered trademarks of Zotefoams plc.

It can seem bewildering when presented with the various conversion options, foam grades, densities, colours etc. But GWP are here to help!

If you would like free, no obligation advice on the best form of foam packaging and / or inserts for your business, then please speak with one of our friendly and knowledgeable foam converters today.