GWP Group

Foam Case Inserts

Custom foam case inserts that eliminate damage, minimise cost of returns & enhance customer satisfaction

Are experiencing a high or unacceptable level of damages to your tools, or products in transit?


If your answer is yes, then your business should take advantage of custom designed foam case inserts. Utilising the latest software and performance calculations, custom case inserts can offer a precise level of protection.


This, in turn, eliminates transit damage, reduces your costs of returns and replacements, and enhances your reputation across your customer base. This can ultimately lead to improved customer retention and repeat business.

I was very pleased with the quality and appearance of the cases and inserts, and would specifically mention the high quality engineering of the foam case inserts. This was far better than anything that we have ever had before. GWP spent many hours designing, re-designing and speaking to us to absolutely nail the requirement, which has been achieved and then some.

Adrian Sorsby | Balluff Field Sales Manager

7 ways foam case inserts can influence your business profitability

  • By preventing damage in transit, costs of customer returns and replacements is eliminated
  • Lower (or eliminated) customer returns means the associated admin costs are also reduced
  • Far Less stock is “written off” as unfit for sale
  • Costly delays to projects, caused by equipment arriving damaged on site, can also be avoided
  • Reliable supply enhances your company perception, aiding brand loyalty & repeat business
  • Calculating performance of the foam ensures inserts fully optimised for cost-effectiveness
  • Sourcing the case and inserts together enhances protection and is  more cost effective

Why is transit damage such a problem?

Damage caused to expensive or critical items in transit can result in major problems for your business.


From the expense and administration involved in organising replacements, to delays in critical projects, such issues can prove expensive.

Equipment case foam insert

Perhaps even more damaging however is the effect that unreliable supply of products or equipment can have on your business, resulting in the potential loss of repeat business and a poor brand perception.

Case Inserts designed specifically to eliminate damage

The vast majority of foam converters, when faced with the challenge of protecting items, will mistakenly compromise the solution by including much more foam than is required.


This is counter productive in that it both costs more in materials, and actually reduces protection.


GWP Protective, however, takes a more scientific approach.

Free Guide: 15 crucial considerations for protection

We are one of very few designers to use cutting edge software which accurately predicts and calculates the ideal foam thickness, density and surface area for maximum product protection . This approach can vastly reduce shock damage in transit.


This software accurately predicts cushioning performance of the foam case inserts, based on extensive test data, across a wide range of expanded polyethylene materials.


Your business can, therefore, benefit not only from having a package which is bespoke to your products but also from the optimum levels of cushioning protection it provides.

Foam Case Insert examples and applications

View a selection of foam case inserts and their typical applications. Please click the individual thumbnails for a larger view.

A proven strategy to reduce both damage and costs for your business

By specifying custom foam case inserts that are engineered to provide calculated levels of cushioning protection, you can ensure the safe transit of your important items. You can also eliminate delays, eradicate the costs associated with returns and ultimately improve customer satisfaction.


Plastazote – the material used to create high performance case inserts – is well known for being lightweight, tough, flexible and moisture resistant. It is also chemically inert and resistant to oils, solvents, dilute acids and UV light.


It is available in a large range of colours too, offering brand consistency and additional customisation options. As well as case inserts, Plastazote foam inserts can be used in a multitude of stand-alone packaging applications.

Waterproof case foam insert

Improved reputation in the reliable supply of high value items, by reducing the costs associated with damage, can also increase sales through additional repeat business.


Alongside this high level of transit protection that ensures items arrive undamaged, it also ensures crucial projects and / or jobs are not hindered by delays.

Choosing a case for your inserts

Of course, case inserts without a suitable exterior case will not always be able to offer the levels of protection you require. For the optimum level of protection, choosing from a huge range of custom built or branded exterior cases is of the utmost importance.


Being completely independent, it means that GWP Protective can offer you the widest range of protective cases available from a single source.

Foam insert manufacture

Sourcing both case and foam together further benefits your business.


A common issue when specifying cases and foam from differing sources is that, not only is the cost higher, but the fit and compatibility between product, foam and exterior case can be less than perfect.


With a well equipped, modern conversion facility, skilled production team and experienced designers, GWP Protective can reduce your costs through being a genuine single source case and foam supplier. Being completely independent, we are able to provide impartial advice on the optimum exterior case for your specific application.

Why choose GWP Protective as your foam case insert supplier?

Put simply, your company can partner with a case insert manufacturer that offers you over 25 years’ experience in high level foam design and conversion.


The modern, clean production facilities where your inserts will be manufactured are supported by an in-house design department with vast experience of creating bespoke foam inserts and equipped with the very latest 3D CAD systems and digitising hardware.


Any irregularly shaped items can be profiled straight onto the CAD system to generate drawings for your approval and ultimately transferred straight to the advanced CNC manufacturing equipment for production.


This guarantees a very closely engineered fit between product and the bespoke foam case inserts for maximum product protection.

Foam conversion

This expertise in both design and manufacture is complimented by the highest levels of customer service at every stage of the process.

Free Guide: 15 crucial considerations for protection

Find out more

Benefit from free, impartial advice on the best solution for your business, no obligation quotes, and a sampling service to ensure complete satisfaction before manufacture. Contact a member of the team today for more information.

Free Quote / Advice


Get a quick, free, no obligation quote or impartial advice by completing the form below.

First Name (required)
Last Name (required)
Email (required)

For details of how GWP Group will treat your data, please view our Privacy Policy. Your info will not be shared with any third party.

Expert Foam Conversion… 


Use the links below to see the engineered foam inserts, foam packaging and other protective solutions available from GWP Protective.

Benefits for your business… 


Select from the options below to see how you can reduce costs, eliminate damages and streamline your operations

Related information… 


Please use the links below for further information on foam inserts / protective cases that you may find interesting and useful

6 signs you need foam inserts
Transit cases - how to decide which is best for your business
Plastazote foam - what is it and why should you be using it

Free, no obligation advice… 


Click below to discuss your upcoming requirements, difficulties you are facing or to simply get advice from one our experts.

Could foam case inserts have a positive impact on your business’ operations?