Packaging foam is valuable to many different types of businesses. Businesses use it for shipping, packaging, storage and protecting fragile items. Foam packaging basics consists of three main foam packaging forms. Foam packaging manufacturers create it as loose fill, preformed and wrap.

Packing foam prevents items from movement and breakage during shipping. Foam packaging prevents items from damage during moving. Clerks use foam wrap to protect fragile purchases made by customers. When considering how foam packing can benefit your business, think about the following:

1. Which form of foam packaging do you need?

2. What purpose will your foam packaging serve?

3. Will you use the packing foam for shipping?

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Consider purchasing foam packaging loose fill for light support

You can purchase foam packaging in the form of loose fill items, which many call packing peanuts. This loose fill foam is great for items that need only a small amount of extra support in the box. With loose fill foam packaging, the shape of the item doesn't matter; it fills in the empty space on the sides between the item and the shipping box. Pile them on top of the item to prevent it from falling if someone turns the box upside down.

I recommend: Purchase loose fill packing foam from foam packaging companies such as Fast-Pack.com, which offers the fill and dispenser. Apply foam fill recycling tips from GreenGuardian.com to reduce the cost of foam packaging.

Choose strong protection with preformed foam packaging

Preformed foam packaging has indentions that match the item, so the item fits inside the preformed foam pieces. The pieces typically go on each side of the item and then fit tightly into the box. This type of packaging provides maximum foam support for shipping and moving fragile items; however, you must customize preformed foam to the item to give the most support. Purchasing foam pieces and cutting them as desired will work with less stability.

I recommend: S&S Packaging Products offers foam packing material such as preformed corners. You can purchase foam packaging materials like die-cut foam from Protexic Brands.

Use foam packaging wrap with fragile items

Foam packaging wrap creates an additional layer of protection when you wrap it around individual items. When selling glass or other fragile items, use foam wrap to keep items from hitting one another and causing damage. You can wrap small breakable items, computer monitors or television screens to protect them during a move.

I recommend: Check out foam packaging supplies such as rolls of foam wrap from Bubble and Foam Packaging. Another company that offers these products is PackagingSupplies.com.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  Consider purchasing foam packaging in bulk to save money. Save even more by recycling the packing from items you receive.

If shipping products or materials is a mainstay of your business, protecting those goods while in transit is key to your success. To prevent items from getting damaged during shipping, foam packaging may be the answer. With dozens of configurations available, including foam rolls, Styrofoam packaging peanuts, foam pouches, foam sheets, convoluted foam, cohesive foam, foam tubes, plank foam, and anti-static foam, there’s probably a foam packaging product that will work for you.

When choosing which type of foam packaging to use, keep the following questions in mind:

1. How fragile is your product? (Instapak Quick foam packaging may be your answer.)
2. Is the item you’re shipping a standard box or rectangular shape or is it an odd shape? (You may need custom foam packaging.)
3. How heavy is the item you’re packing? (Plank foam can protect corners.)
4. Can your item be damaged by static? (Anti-static foam packaging is available.)
5. Is it important to you or your customers that you use recycled or bio-degradable foam packaging?

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Foam rolls

Foam rolls come in thicknesses ranging from 1/16' to 3', are typically 12', 24' or 36' inches wide and may be up to 75' long. For easy reconfiguration to fit your boxes and materials, choose perforated foam rolls. Most vendors offer discounts when you purchase more than one foam roll.

I recommend: Uline Shipping Supplies, StarBoxes.com, Paper Mart Packaging Store and BubbleandFoamPackaging.com offer some of the widest selections of foam rolls.

Styrofoam packaging peanuts

A popular packaging choice, packing peanuts fill empty space in packages and interlock to avoid settling. Styrofoam packaging peanuts are typically a low-cost item and a warehouse favorite due to their light weight. If you're concerned about the environment, choose bio-degradable packing peanuts or recycled packing peanuts.

I recommend: At StarBoxes.com, you can find bio-degradable packaging peanuts and anti-static packaging peanuts in addition to traditional Styrofoam packaging peanuts. Global Industrial offers packing peanuts along with a dispenser for easy, no mess packing. Find more suppliers for packaging peanuts at Business.com.

Foam pouches

When you want to ship small items in envelopes but want added protection, consider foam pouches. These handy items come in a variety of sizes that fit within standard envelope sizes.

I recommend: For a good selection of foam pouches, visit PackagingPrice.com.

Convoluted foam packaging

To protect delicate equipment, such as cameras, tools, instruments or electronics, use egg-carton-shaped convoluted foam packaging. Convoluted foam packaging is interlocking to protect items and can be cut to your desired size.

I recommend: Find convoluted foam and a wide range of other foam packaging options at BubbleandFoamPackaging.com.

Instapak Quick foam packaging

Instapak Quick foam is a form of expandable foam in a bag that is ideal for fragile shipments. The expandable foam packaging molds to the shape of whatever you are shipping for ultimate protection and eliminates messy cleanup. Some types of expandable foam packaging require a bag warmer for inflation.

I recommend: Uline Shipping Supplies and BubbleandFoamPackaging.com offer a wide array of Instapak Quick foam packaging to fit a number of standard box sizes.

Custom foam packaging

When your products and materials require the utmost protection, consider custom foam packaging options that are designed with your specific materials in mind.

I recommend: UFP Technologies creates single-use and reusable custom foam packaging products for fragile electronics, sensitive instruments and more.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  If you ship odd-shaped products, consider using cohesive foam packaging, which sticks to itself to form a protective shell.
• •  Foam packaging in the shape of a tube is ideal for long, slender items.
• •  Foam rolls can be bulky; make sure you have adequate storage space for them.

The pricing and costs of foam packaging is a concern for some businesses because they use it extensively. Businesses use packing foam to ship ordered products to customers. Foam packaging is also used to safety store items. Glassware and novelty stores that sell fragile items use foam wrap to protect items consumers purchase.

Companies that use foam packing want to keep their prices low by finding the best deal on foam packing supplies. Businesses can save on foam packaging materials in many ways. When planning your foam packaging budget consider the following:

1. How often do you use foam packaging?

2. What type of foam packaging do you use most often?

3. How much storage room do you have for foam packaging?

Action Steps
The best contacts and resources to help you get it done

Purchase foam packaging in bulk

If you ship many items, consider buying foam peanuts and other foam packaging supplies in large quantities. Most companies offer cheaper per unit rates on larger orders. While this can save your business money, you must also consider space for storage. Many companies that sell foam peanuts also sell a foam peanut dispenser. This is useful if you use large amounts of loose fill foam packaging.

I recommend: Uline offers foam peanuts in 20 cubic feet bags for $25 to $28. Ask for a special pricing quote if you order over 40 bags. Packaging Price also offers pricing discounts.

Recycle foam packaging from shipments you receive

Most companies that ship items also purchase items wholesale to resell. These products may come in boxes with foam packaging. Businesses also receive parts, pieces, and office supplies. When you receive foam packaging with these items, save it for reuse. Not only is this a good practice for the environment, it also saves you money. You can empty loose fill foam packaging into large storage tubs or boxes.

I recommend: Montgomery County gives suggestions on how to recycle foam packaging. Sealed Air offers a foam packing return recycle program.

Choose a packaging foam distributor with a variety of products

Carefully choosing your foam packaging supplier can save your company money. Many manufacturers give discounts on large orders. These discounts include cheaper rates and even free shipping. If you use foam packaging for shipping, you will need a variety of packing types and sizes on hand. Choosing a foam packing distributor that offers a variety of products will streamline your ordering process.

I recommend: United Foam offers shipping foam, foam pouches and more. Office Depot sells a variety of foam for shipping such as foam sheets for under $15.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  When purchasing your foam packing products, consider selecting packing foam in colors. Your customers will appreciate the colorful surprise when they open their package.

Foam packaging, while once restricted to loose-fill foam peanuts, now includes a wide range of foam products, including preformed foam, various types of foam wrap and even anti-static foam. Each type of foam packaging material differs in the way it is manufactured and the function that it serves. By understanding the differences between all of these varieties of foam packaging, you can ensure that whatever you need to package is safe and secure.

Action Steps
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Loose-fill foam

Loose-fill foam, also known as foam peanuts or packing peanuts, has been around for many decades and was devised as an early form of void-fill material for packaging fragile objects. Loose-fill foam is still widely used because of its ease and low cost, while many biodegradable and plastic alternatives, as well as reuse and recycling programs, offer users a chance to pursue more environmentally friendly options.

I recommend: Read more about the foam used to make loose-fill foam peanuts and how it is distinguished from other types of foam at Wise Geek.

Preformed foam

Preformed foam, or custom foam, is a type of foam packaging that is either manufactured or die-cut to fit the form of the object being packaged. Some specific types of preformed foam include corner pieces, built up foam panels that cover the side of an object and channel foam that fits along an object's edge.

I recommend: Get a concise definition of how preformed foam is made, as well as examples of several types of preformed foam, from S & S Packaging Products.

Convoluted foam

Convoluted foam is a type of foam in which the texture has been altered to make the foam a softer cushion. This type of foam is used for packing objects that are more fragile or need more flexibility in the packaging, such as fruits and other produce.

I recommend: The Polyurethane Foam Association offers a concise definition of convoluted foam and how it is made.

Cohesive foam

Cohesive foam is either manufactured using a formula that gives the foam cohesive properties, allowing it to stick to itself without using any type of adhesive, or it has an adhesive laminate applied to it that allows it to stick to objects without the use of tape or glue. Cohesive foam typically comes in sheet or pocket form.

I recommend: Sealed Air offers a definition of cohesive foam and suggests several uses for the product.

Foam wrap

Foam wrap is a popular form of foam packaging that comes in various roll sizes and foam thickness, and can be used either as a complete roll or as pieces cut from foam sheets. Foam wrap is also a popular form of packaging because it can be made into foam pouches by folding the foam over and taping the sides together.

I recommend: Get the definition for two varieties of foam wrap available from American Carton & Polybag.

Anti-static foam

Anti-static foam is used to dispel the static electricity produced by the motion of transporting a package. Anti-static foam can come in a variety of forms, including foam pads and rolled foam wrap, and is typically used for packaging products that may be damaged by electric charges, such as cameras, computers and other electronics.

I recommend: Quality Foam Packaging offers specific definitions for several varieties of anti-static foam.