"If you are using any equipment, carry or sample case, adding foam inserts can offer a huge range of benefits - improving protection, eliminating damage, enhancing appearance, boosting productivity on site and much more besides"
Custom foam inserts – for cases, boxes, or totes – can be utilised in a number of ways.
Perhaps you are experiencing high volumes of damage to your products, equipment, or components during transit. Or maybe expensive tools keep going missing on site. Do you need a more professional way of presenting your samples in sales meetings to boost orders? Or are you looking to gain brand differentiation in saturated, luxury retail markets?
Regardless of your application, industry or budget, custom foam inserts can help you achieve all of the above. In turn, this could have a direct, positive impact on the efficiency and profitability of your business.
Custom Cut Foam Inserts
A range of custom foam insert options suitable for any equipment, case, application or budget
Latest foam CNC routers allow for high quality and cost effective inserts
Water Jet Cutting
Intricate designs manufactured effortlessly using 65,000 psi water jet
Ideal for simple, high volume foam packs with a high quality finish
Add detailed, crisp and well defined logos, instructions and more
Foam Insert Advice & Guides
A huge selection of guides, information and advice to help you source the optimum case insert / foam packaging for your business
FAQs / Additional Info
A selection of the most commonly asked questions regarding foam inserts, packaging, material, and protective cases
What are foam inserts used for?
Although typically used for the purpose of cushioning tools, equipment or products within an outer case or packaging – which prevents damage in transit – foam inserts can be used for a wide range of additional applications. This includes aiding retrieval of items, presenting samples and even acting as part of luxury packaging.
Are foam inserts for use in boxes or cases?
Plastazote® foam inserts tend to be used with protective cases, including waterproof, aluminium, or custom-built options. They can also be used within sample presentation cases. Saying that, GWP Protective can provide a wide range of foam inserts for boxes – used with high volume corrugated packaging – as well as retail applications and even foam dunnage for use in returnable handling products.
What are foam inserts manufactured from?
The foam inserts that GWP manufacture are nearly always manufactured from Plastazote® (although for single trip applications where the outer packs are cardboard, Stratocell or Ethafoam is more likely to be used). This is due to the inherent properties of Plastazote® (providing excellent performance), its relatively low cost, the range of options and the high-quality appearance that can be achieved.
What colour foam inserts are available?
Plastazote® comes in a range of more than 20 colours, allowing for you to choose a shade that closely matches your company’s logo and / or branding. Please note however that not all colours are available across all grades. A GWP adviser will be happy to provide information on the options available and suitable for your specific application.
I’ve seen two tone foam inserts – how are these made?
Using layers of different coloured Plastazote® can create foam inserts with a unique and attractive appearance. This is most commonly seen with a black or dark foam laminated on top of a contrasting colour. When machined, the brighter colour underneath shows through to create a striking visual effect (which can also help with identifying missing parts or equipment too).
What is a shadow board?
A shadow board is where different coloured foams are layered on top of each other, with any recessed pockets being a different colour to the foam on top. Apart from looking great, this can actually help the identification of any parts not returned to their specific place within the case or toolbox, due to the area of brightly coloured foam being visible at a glance.
How can foam inserts protect my items?
The main way that foam inserts protect items during transit or any form of handling, is by providing cushioning within the outer case or packaging. Not only does this stop the contents colliding with each other, but also with the internal walls of the container. Taking this one step further, GWP Protective can calculate the exact levels of foam required to absorb specific levels of shock or impact – offering a truly bespoke (and optimised) level of protection for your items
How should I choose an exterior case for use with my inserts?
Besides foam inserts, GWP can also offer your business a wide range of exterior case options. For example, waterproof cases are ideal for heavy, rough-handling applications, whereas lightweight plastic sample cases are more suitable where handling will be more careful. Other options include metal, custom built flight cases, plastic tote containers and even cardboard boxes. A GWP team member will be happy to offer guidance on the best option for your business.
What are pick and pluck foam inserts?
Pick and pluck foam inserts are a type of foam that is already pre scored, typically into 1 cm cubes, which can be removed by the end user to create a semi bespoke insert. Typically supplied with waterproof cases such as Peli (or Storm, SKB or Nanuk etc.), these are a good choice for a one-off project (e.g. hobby equipment, camera cases and so on). For industrial applications however, GWP would always recommend custom Peli foam cutting / bespoke inserts.
You can select from the widest range of branded cases from a UK supplier, including Peli, Nanuk, SKB, Zarges, Explorer and more…
Any case you source from GWP can be customised with foam inserts, print and more. And you can specify custom flight cases too!
Being independent means that you can benefit from truly impartial advice on the best case for your application, industry and / or budget
Protective Cases / Outer Container Options
A huge range of protective cases, handling containers and transit packaging, suitable for every application, industry or requirement
Why choose GWP for your Foam Case Inserts?
Engineered foam inserts and packaging products that provide high quality appearance and the exact level of performance you require
Foam Design Expertise
GWP one of the UK’s largest and longest established foam converters, employing an expert design team and cutting edge software / equipment
No more guesswork – your foam inserts will be created using advanced software that calculates optimum protection levels for your specific items
Your foam inserts will be manufactured at GWP’s Wiltshire production facility, ensuring the highest quality, short lead times, and competitive pricing