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Phone GWP Protective - 01722 416 440
01722 416 440
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GWP Packaging

Corrugated cardboard packaging expertise and innovation

GWP Protective

Widest range of protective cases with custom foam in the UK


UK leading independent Correx® packaging manufacturer

GWP Conductive

Providing cutting edge ESD safe packaging for 30+ years

GWP Coatings

Supplying sheet plants with coated corrugated material

Reduce packaging costs

A range of strategies and ideas to reduce your ongoing packaging costs

Protective packaging

Protection for your products and equipment to prevent costly damage in transit

Improve packaging efficiency

Streamline your operations, enhancing efficiency and productivity

Environmentally friendly packaging

Minimise the environmental impact of your packaging and business

Packaging design service

Custom packaging to your exact requirements, designed by an award winning team

Packaging guides and blog

A range of guides, tips and detailed articles to improve your packaging

Case studies

Examples of successful packaging, and how your business can benefit

Packaging markets

Specific industry knowledge and expertise relevant to your business

Quality standards

Accreditations / standards to ensure you get the highest packaging quality

Packaging news at GWP

The latest news, events and community projects happening at GWP Group

Foam Lined Boxes

Custom Design

Foam inserts, printing and more

UK trade supplier

Tailored pricing on all orders

Case and foam experts

More than 25 years experience

Foam lined cardboard boxes

Cost Effective Mailing Boxes

Cardboard boxes with foam lining for protection whilst shipping

Perfect for use as ecommerce postal boxes – where your business needs to ship different combinations of products from order to order – foam lined boxes protect items during transit and help with staff efficiency and fulfilment times.

The convoluted foam helps brace the contents, cushioning and eliminating movement. Supplied ready assembled, foam lined postal boxes can help reduce packing times, and can be printed externally with logos, graphics and more. Read More

Available Colours:

Black foam
Grey foam
White foam
Turquoise foam
Light blue foam
Pink foam
  • No obligation (and no pressure) quotes for any case
  • Impartial advice from UK based experts
  • Competitive pricing and full customisation options


More info on Foam Lined Boxes

Whilst foam end caps provide arguably the highest level of protection when shipping products, they have one potential limitation – they are tailored to a specific product and / or pack size.

This means they are not suitable for businesses – such as those selling online – that ship varying combinations of products depending on customer orders.

This is where foam lined boxes can be useful. As they work across a range of products, they can be used across a wide number of different items, and combinations of these.

And whilst the overall size of the outer cardboard boxes can be custom manufactured bespoke to your requirements, they otherwise all work in the same way. The convoluted foam to brace the items within (i.e. hold them in position) which in turn means that the do not move around whilst in transit. This, in turn, prevents damage.

Besides this, the foam lined boxes can protect products in a number of other ways. This includes cushioning against shock, impact, and vibration, whilst the non-abrasive foam material also protects the surfaces of the product being shipped too.

Additional benefits of foam boxes

Foam lined cases and boxes can also help your business in a number of other ways.

For example, the boxes can be supplied ready assembled, eliminating the time taken to assemble them (helping improve efficiency and fulfilment velocity).

As the boxes can accept varying products, it also helps to reduce the size of your packaging inventory. This can not only reduce costs (through economies of scale when purchasing) but also further improve packing times (as there is less time spent selecting the appropriate box).

And finally, all mailing boxes with foam inserts can also be printed with logos, graphics, instructions and more. They are also available in white or brown (Kraft) corrugated material, with the foam lining available in various colours too.

Key Benefits of foam lined boxes at a glance

  • Reduces packing times (staff simply place items within boxes)
  • Supplied ready assembled to further improve efficiency
  • Minimises transit damage, reducing customer returns (and associated costs)
  • Non abrasive foam also protects product surfaces
  • Single foam lined box can be used for varying products / combinations
  • Ideal for ecommerce shipping where items shipped differ order to order
  • Convoluted “egg crate” foam helps secure items in place
  • Custom sizes and print for exterior boxes available
  • Can also specify foam lining of Correx® (plastic boxes)


Common questions about foam lined boxes

The below highlights the most commonly asked questions regarding foam lined boxes – hopefully answering any queries you may have.

But… if you are still looking for further information, please get in touch. A member of the GWP team will be happy to help.

What size foam lined boxes are available?

Whilst many online sellers of packaging will only offer foam lined boxes in set sizes, by sourcing your mailing boxes from GWP you can specify these to (virtually) any size that you require. This can help you minimise transit costs (by minimising the volume / size of box you are sending) and can also allow them to be tailored to specific guidelines, such as Royal Mail PIP.

What foam is used to line boxes?

Typically, either Stratocell or Ethafoam will be used to line corrugated packaging. These closed cell foams are cost effective, easy to fabricate, and provide good levels of protection. They are relatively environmentally friendly too.

Are there any benefits to using these instead of foam inserts?

The main benefit that foam lined boxes have over types of insert such as foam end caps, is that they are not tailored to a specific product (as per foam blocks also). This means that if your business frequently sends lots of different combinations of items – such as ecommerce orders – then this can be easily accommodated whilst still providing good levels of protection.

What does “convoluted foam” mean?

Convoluted foam – also referred to as “egg crate foam” – is the name given to the undulating foam sheets that have a series of peaks and troughs machined on to the materials surface. These are used to help brace the items within the foam, minimising movement and thus reducing damage in transit.

What are foam slider boxes?

Foam slider boxes are a type of package where two sheets of foam are able to “slide out” of the main box, which the product can be placed into. These can be slid back into the outer carton ready for shipping.

Is foam better than polystyrene?

Polystyrene is only effective at protecting items for one drop – making it unsuitable for many products to be shipped via couriers. It is also not environmentally friendly. Foam on the other hand maintains performance over multiple drops / impacts and can be recycled at the end of its life as well.

Free Quotes / Advice

Find the ideal foam lined boxes for your business

Having more than 30 years’ experience in both foam conversion and as corrugated box suppliers, GWP are perfectly placed to provide your business with foam lined packaging of the highest quality.

But this is not all, as you can also benefit in a number of other ways. Competitive pricing, a dedicated project / account manager, access to experienced designers for specialist requirements, impartial advice, and sourcing all of your transit and retail packaging from a single supplier.

And, as all packaging supplied is completely tailored to your business, all quotes (which are also free and no obligation) are too.

Alternative Foam Options

Foam options regardless of your packaging requirement

GWP Protective supplies a huge range of foam packaging options – the widest in fact from a single UK foam converter. Please see below for the range of foam end caps, linings, case inserts and more that your business can source.

Stratocell packaging


Versatile foam packaging options for your business

Ethafoam packaging inserts


Perfect foam option for single trip shipping requirements

Two custom foam end caps protecting industrial part

End Caps

Low cost, low material transit protection solution

Foam packaging blocks

Foam Blocks

Simple, cost effective packaging inserts for shipping

Stratocell foam packaging

All Foam Packaging

All options for using foam for presentation applications

Foam Trays

All Foam Options

More than 25 years experience in foam conversion

Compatible Outer Packaging

Packaging available to be used with foam linings

Corrugated packaging

Corrugated Boxes

Single trip corrugated cardboard packaging boxes

Sample cases

Protective Cases

Waterproof, aluminium, lightweight plastic & custom

Unboxing packaging (ecommerce)


Ecommerce packaging perfect for online sellers

Correx postal boxes


Durable corrugated plastic boxes for shipping

Specialist packaging coatings

Anti Static

Specialist packs for protecting ESD sensitive items

Corrugated packaging

All Options

View all of the outer packaging options available

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    Here to Help

    Contact a member of our sales & support team directly

    Dan Wellings

    Dan Wellings

    Product Adviser
    01722 416 440

    Richard Coombes

    Richard Coombes

    General Manager
    01722 416 440

    Ian Heskins

    Ian Heskins

    Sales Director
    01793 754 444

    Phone GWP Protective

    01722 416 440

    Mon – Fri 08.30 – 17.00

    Email GWP Protective

    Email a case / foam expert

    See how foam lined boxes can offer improved protection for orders and increased packing speed...