Custom foam inserts for boxes
If your business ships high volumes of valuable or fragile consumer goods, foam packaging, specifically custom foam inserts for boxes, is vital.
Foam packaging is typically a polyethylene material used within cardboard boxes. Foam packaging inserts cushion products during transportation and handling, preventing damage. Commonly used packaging foam includes Stratocell and Ethafoam.
At GWP, we have more than 30 years experience of foam conversion for packaging applications. We can design and manufacture foam box inserts that eliminate costly damage, use minimal material, and are easy to assemble/pack. We can also supply the outer corrugated packaging alongside your custom foam packaging and foam inserts for cases, supply chain containers, and retail packs.

Custom foam packaging inserts
No matter the size, weight or value of the products your business ships, we can supply a range of foam packaging, box inserts and end caps that prevent damage during transit.
Recycled foam packaging
There are a number of recycled foam packaging materials, helping your reduce the environmental impact of your business.
Alternative foam inserts for packaging
As specialists in foam conversion, we can supply a range of alternative foam packaging inserts for virtually any application.
More info
It can be tempting to cut corners when shipping fragile products.
Both industrial and consumer items such as TVs, laptops, and even white goods such as washing machines, can be packed to a budget. However, when even a surface blemish or scratch renders the product unfit for sale, items damaged in transit can quickly make cheap packaging uneconomical.
However, low-density polyethylene foam packaging can provide a cost-effective solution for preventing damage during shipping.
Foam box inserts
Custom foam packaging offers protection in transit from shock and vibration, which can reduce the costs to your business associated with returns and damaged products. This is, of course, in addition to the intangible expense of dissatisfied customers and the potential loss of repeat business.
As such, well-engineered foam packaging material can be cost-effective for both high- and low-volume product lines.
Custom packaging foam
Whilst simple foam lining and basic foam blocks can be effective, foam end caps created from materials such as Ethafoam and Stratocell are the best option for protecting items in transit.
Custom foam end caps are widely used to protect electronic equipment and other fragile products against shock, vibration and mishandling that may occur in your delivery or courier network.
They also offer the most efficient use of material, making them not only cost-effective but also more environmentally friendly (particularly when compared with expanding foam packaging or foam packaging chips).
Foam packaging FAQs
What is foam packaging made from?
Foam packaging can be made from various materials. However, the most widely used foams are the Stratocell and Ethafoam ranges from Sealed Air, which are polyethylene-based materials. Plastazote®, a cross-linked polyethylene foam used for more specialist applications (such as Peli case inserts), is also popular.
How does foam packaging protect my products in transit?
Foam packaging inserts can protect your products in several ways. They can help to “brace” your products within the outer container, preventing damage through collision with other contents or the walls of the external box. Foam can also absorb some of the shock if a parcel is dropped or mishandled by allowing a more controlled deceleration of the product on impact.
Are foam-lined boxes suitable for my requirements?
Foam-lined boxes are a good option when you are distributing a varied product inventory and require a level of cushioning protection. However, as a foam lining isn’t generally optimised to suit specific products, it may not be the most effective option for a lot of applications.
What are foam end caps?
Foam end caps are fabricated foam items you place over the ends of the item you are shipping before putting it into the outer packaging box. This holds the item in place and provides cushioning on the corners and edges. They are also very efficient in terms of material usage (and therefore costs).
How do you manufacture foam packaging?
Packaging foam is converted at GWP Protective’s modern facility (in Wiltshire) in several ways. These include die cutting, laminating, waterjet cutting, and pressing. In addition, several finishing processes ensure your foam packaging performs precisely as required. We have provided foam conversion services at GWP for more than 30 years.
Does using foam affect packing times?
Depending on the type of foam product you select, using foam packaging can slightly impact your packing times. This is mainly due to adding another process for staff during packing. However, you should weigh this small drop in productivity against the vast decrease in resources required to handle and process damaged and returned items that using foam packaging can achieve.
Foam packaging manufacturers
With over 30 years of experience designing and manufacturing foam packaging, we can offer your business a number of real, tangible benefits. One of the most significant is the ability to source both your foam and exterior box—be it corrugated cardboard, Correx®, or plastic—from a single source.
This has two obvious benefits.
Firstly, eliminating the need for separate suppliers can minimise costs and administration. Secondly, the quality and fit of the foam with the exterior pack are also much better, improving quality, performance, and protection.
We typically manufacture your foam box inserts from Stratocell or Ethafoam materials, both available as recycled foam packaging grades. As official fabricators of the Sealed Air range of Polyethylene foams, we can cost-effectively produce packaging foam cut to size to protect your business’ fragile components or products in transit.
Custom packaging foam experts
Besides this, your business benefits from an allocated point of contact who can guide you through the entire design and quoting experience. Alternatively, if your company has previously used similar packaging, our experts can ensure your exact requirements are met and, wherever possible, exceeded.
So, if you can’t find the right foam packaging for your business, are looking for a more cost-effective option or simply don’t know where to start, we can help. Get in touch today for free, no obligation advice or a fully tailored quote on any foam packaging your business needs.
All foam options
Corrugated boxes
Other outer packaging
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