Packaging with foam inserts
Foam-fitted packs that hold the product in one position, absorb shock and let a packer close a box in seconds with no judgement calls.
The problem
What usually goes wrong
Void fill protects a product by accident. It stops movement only if the packer uses the right amount, in the right places, every single time.
For anything fragile, precision-finished or high value, that variability is the problem. Two identical orders can arrive in completely different condition.
Foam-fitted packs remove the judgement. The product goes in one way, it cannot move, and the pack takes the same time to close whoever is on the bench.
Typical pack
Packaging components we usually specify
- Bespoke corrugated box with a fitted foam insert
- Closed-cell foam cavities cut to the product profile
- U-foam profiles for edge, corner and rail protection
- Foam rolls and sheets for interleaving and surface protection
- Anti-static bubble and foam for electronic assemblies
- Two-part cap-and-base foam sets for heavier products
Materials
Relevant materials and board grades
- Closed-cell foam for repeat impact absorption and clean cavity edges
- Softer foams and foam rolls where surface finish is the priority
- U-profile foam for framed, panelled or extruded products
- BC double wall outers where the foam set adds weight and the pack is stacked
- E and EB flute outers where the pack is customer-facing
In-house
Our manufacturing and assembly capabilities
- Box and insert designed together in Letchworth, so the fitment and the box actually match
- Prototype the insert, test it with the real product, then refine before the production run
- Assembly and kitting: boxes supplied erected with foam fitted, ready to load
- Component sets built as a single part number for your stores
- Short runs and one-offs quoted without tooling charges
Stock holding
How we hold stock for you
- Hold assembled foam-fitted kits with us and call them off as production needs them
- Volume pricing without giving up your floor space to bulky foam sets
- Combined deliveries with the rest of your packaging on our own vehicles
Accreditations
Relevant accreditations for this sector
- FSC C214479
- BRCGS Storage & Distribution
- Verified Carbon Standard
Real example
Removing the guesswork from a fragile despatch
A customer packing a fragile instrument was using a double wall box and a generous amount of bubble wrap. Damage rates varied depending on who packed it, which made the problem hard to argue with the courier.
We prototyped a two-part closed-cell foam set inside a bespoke BC box, suspending the instrument clear of every face, and supplied the packs assembled.
Pack time halved, damages became rare enough to be exceptional, and because every pack is now identical, any claim is straightforward to evidence.
Sector enquiry
Send us the product, we'll prototype the insert
Post us a sample or send drawings. We will design the box and foam together and send a prototype for you to test before committing.
- Product dimensions, weight and any fragile faces
- Whether anti-static protection is needed
- How many you pack a week
- Whether you want the packs supplied assembled
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