Foam Material

Foam Assemblies that Meet Every Packaging Need

Protect your valuable shipments with the ideal foam solutions from Packaging Technology. Achieve superior cushioning with lightweight efficiency, durability, and moisture resistance. No matter the industry, our team of engineers can design custom inserts and protective components that ensure delicate equipment arrives safely and intact. We take pride in being industry leaders in sustainability and providing reusable options.

Engineered Polyethylene Foam

Polyethylene foam is a type of closed-cell foam widely recognized for providing superior protection during product transit. It is an excellent choice for packaging fragile goods due to its outstanding vibration-dampening, shock-absorbing, and insulating properties. By utilizing polyethylene foam, we are able to reduce packaging material requirements, resulting in a smaller overall footprint. This not only lowers material costs but also reduces shipping expenses for our customers. In addition, our recycling process allows us to reclaim and recycle nearly 100% of waste material using our densifier, supporting your ongoing commitment to sustainability.

Furthermore, polyethylene foam is highly versatile and can be custom-cut, routed, or laminated to meet the specific protection requirements of any product. Its lightweight nature makes it easy to handle and assemble while maintaining structural integrity and durability. Combined with its moisture resistance and long-lasting performance, polyethylene foam remains one of the most cost-effective and environmentally responsible packaging solutions available today.

Pregis Plank Foam: Engineered Protection for High-Value Products

Pregis plank foam (PolyPlank® engineered foam plank) is a high-performance polyethylene foam designed to safeguard valuable items across industries like electronics, automotive, aerospace, and medical equipment. This closed-cell foam plank is extruded and laminated to offer exceptional cushioning, durability, and versatility for custom packaging solution.  From delicate circuit boards to heavy automotive components, Pregis plank foam delivers reliable protection that reduces damage, lowers costs, and enhances customer satisfaction.

Pregis’s engineered foam planks can be fabricated into custom inserts to securely cradle products. The foam’s dense, uniform cell structure absorbs shocks and vibration during transit, preventing impact damage to sensitive equipment. At the same time, it remains lightweight and easy to handle, adding minimal shipping weight despite its robust protective performance. In short, Pregis plank foam provides “best of both worlds” packaging – tough on protection, light on weight – making it ideal for safeguarding high-value products in demanding environments.

    Key Features and Benefits

    Superior cushioning

    Pregis plank foam offers outstanding shock absorption and vibration dampening, keeping fragile items safe from drops, bumps, and jolts. The material can withstand repeated impacts without losing its cushioning performance, ensuring products remain protected through multiple shipments or rough handling. This high-impact durability translates to fewer product damages and returns.

    Non-Abrasive & Clean

    The foam’s fine closed-cell structure is non-abrasive and lint-free, meaning it won’t scratch delicate surfaces or shed particles. Even Class A finishes and sensitive electronics stay pristine – the foam produces no dust and avoids marring polished or painted parts. Your products arrive in perfect condition, with no foam residue to clean off.

    Moisture & Chemical Resistance

    Closed-cell polyethylene construction makes the plank foam highly resistant to water, moisture, and most chemicals. It won’t absorb liquids or degrade in damp conditions.  This moisture resistance is critical for electronics and medical devices, and it allows the foam to perform in humid warehouses or during international shipping. The foam’s chemical resistance also means oils, greases, or solvents encountered in automotive and aerospace environments won’t compromise its integrity.

    High Strength-to-Weight Ratio

    Pregis plank foam is remarkably strong yet lightweight, providing robust protection without adding bulk. Its high strength-to-weight ratio means you get solid structural support and cushioning while keeping shipping weights (and costs) low.  The foam plank maintains its shape under load and impact, offering reliable bracing and blocking for heavy components. Meanwhile, its low weight helps improve handling ergonomics and can reduce transportation fees.

    Reusable Durability

    Unlike one-and-done packaging materials, Pregis foam planks are durable enough for reuse. They resist compression set and structural breakdown, so you can use them in returnable packaging and reusable case inserts for long-term savings. Whether it’s a custom tool kit that travels to job sites or a reusable tote in an automotive assembly line, the foam will continue cushioning trip after trip. This reusability not only lowers total packaging cost but also supports sustainability by reducing single-use waste.

    Customization and Versatility

    One of Pregis plank foam’s greatest strengths is its versatility in design. It can be fabricated into virtually any shape or configuration to meet specific packaging needs. Foam fabricators can easily die-cut, saw, rout, and bond these planks into custom inserts, pads, liners, and blocks tailored to your product’s exact dimensions. Need a precise cut-out to cradle a medical device, or a multi-layer insert for an aerospace component? Pregis foam plank makes it possible.

    Customization options are nearly endless. Multiple densities and colors are available, allowing you to match the foam’s firmness and appearance to each application or even create color-coded inserts.  Sheets of foam can be laminated together to achieve custom thicknesses – from as thin as ½ inch to as thick as 12 inches or more.  Standard plank sizes (up to 48″ wide by 108″ long) can be cut to any length or dimension required and complex assemblies can combine different foam grades into one solution. This flexibility means Pregis plank foam adapts to products of all shapes, sizes, and fragility levels.

    Sustainability Advantages

    Pregis is committed to innovative packaging solutions that are both high-performing and sustainable. Plank foam may not immediately come to mind as “green,” but Pregis has taken significant steps to improve the environmental profile of its foam products:

    Recycled Content Options

    The Pregis PolyPlank® Renew™ foam plank contains up to 60% pre-consumer recycled content without any sacrifice in performance. By using up to 60% reclaimed polyethylene in the manufacturing process, this foam reduces dependence on virgin resin and helps conserve petroleum-based raw materials. It delivers the same excellent cushioning and durability with a lighter environmental footprint. Choosing Renew™ foam allows you to meet sustainability goals while protecting your products.

    Recyclability

    Pregis’s foam planks are made from pure polyethylene, which is a recyclable material. Through specialized programs like foam densification, used foam scraps and inserts can be collected and recycled back into useful material instead of landfilled.

    Waste Reduction

    The precision and reliability of engineered foam packaging translate to less product damage and waste. By virtually eliminating shipping damage, Pregis foam helps avoid the environmental cost of producing replacement products and the extra shipping for returns.  Additionally, the foam’s reusability means fewer disposable packaging components are needed over time. All of this contributes to a lower overall environmental impact for your packaging operations.

    Pregis plank foam delivers a compelling combination of protective performance, customization, and sustainability. It cushions against shocks, vibration, and mishandling, ensuring your valuable products reach their destination intact. It can be tailored to any shape or requirement, elevating your packaging to a engineered solution rather than a makeshift fix. And it achieves all this while supporting reuse and recycling, helping you minimize waste. Pregis plank foam truly stands out as a professional-grade packaging material that gives industries from electronics to aerospace a competitive edge in product protection. Whether used in a sales brochure, on a website, or in a technical sales sheet, the message is clear: with Pregis foam planks, your products are in safe hands from the factory floor to the final destination.

    Polyurethane Foam

    Polyurethane foam is a versatile and highly resilient material widely used across industries for its exceptional cushioning and energy absorption properties. It is a closed-cell or open-cell foam that can be precisely engineered to meet specific density, firmness, and performance requirements—making it ideal for protective packaging, gasketing, insulation, and vibration control applications.

    At Packaging Technology Inc., we utilize polyurethane foam to design custom inserts and protective components that ensure delicate instruments, electronics, and equipment arrive safely and intact. The material’s fine cell structure provides excellent shock absorption, impact resistance, and shape retention even under repeated compression.

    In addition to its protective qualities, polyurethane foam offers:

    • Lightweight efficiency — reduces total package weight and shipping costs
    • Excellent flexibility — conforms to complex shapes and contours
    • Durable performance — maintains integrity under stress, temperature shifts, and vibration
    • Sustainability options — available in recyclable and reprocessed grades, supporting eco-friendly packaging initiatives

    From custom die-cut inserts to engineered cushioning systems, polyurethane foam delivers the balance of protection, presentation, and performance that today’s industries demand. Whether used in aerospace, medical, electronics, or industrial packaging, this foam provides consistent quality, reliability, and professional appeal.

    Polystyrene/EPS Foam

    Polystyrene foam, commonly referred to as Expanded Polystyrene (EPS), is a lightweight, closed-cell material ideal for protective and insulating applications. It offers excellent cushioning and energy absorption, making it a reliable choice for end caps, corner blocks, and custom inserts designed to protect delicate products during handling and shipment.

    EPS is also widely used in temperature-controlled packaging for medical and pharmaceutical products, thanks to its outstanding thermal insulation capabilities. Available in white, black/grey, and anti-static pink options, EPS foam can be produced in multiple densities to meet specific protection requirements.

    This cost-effective, shock-absorbing material provides durable and stable protection while remaining moisture-resistant and dimensionally consistent. EPS foam helps reduce product damage, shipping costs, and environmental impact when properly designed and utilized as part of a comprehensive packaging solution.

    Rubber Lite

    Rubber Lite foam is a high-performance, closed-cell foam material known for its superior durability, resilience, and cushioning properties. It offers excellent resistance to impact, moisture, and vibration, making it ideal for protective packaging, gasketing, and sealing applications. Rubber Lite foams are available in a variety of densities and formulations, allowing for precise customization based on the protection level required. This material is also resistant to oils, solvents, and extreme temperatures, ensuring long-term reliability in both industrial and commercial environments.

    Key Benefits:

    • Excellent shock absorption and vibration dampening
    • Resistant to moisture, oils, and temperature fluctuations
    • Ideal for long-term protective packaging and sealing applications

    IMC Material

    IMC (Integral Molded Cushion) material is a durable, cross-linked polyethylene foam designed for applications requiring both structure and flexibility. It combines a smooth outer skin with a resilient core, offering superior surface protection and impact resistance. IMC foam is commonly used for returnable packaging systems, dunnage, and protective inserts for sensitive instruments or components. Its closed-cell construction prevents water absorption and maintains consistent performance even after repeated use.

    Key Benefits:

    • Strong, lightweight, and reusable foam option
    • Excellent impact protection and surface finish
    • Non-abrasive and moisture-resistant for long-term use

    Volara Foam

    Volara foam is a fine-celled, cross-linked polyethylene foam known for its smooth texture, flexibility, and aesthetic appeal. It provides excellent thermal insulation, cushioning, and resistance to chemicals and moisture. Volara is often used in precision packaging, medical devices, automotive interiors, and product display applications due to its clean appearance and consistency. The foam can be easily fabricated, laminated, or die-cut to meet exact design specifications.

    Key Benefits:

    • Soft, smooth, and uniform surface finish
    • Excellent insulation and cushioning properties
    • Chemical, moisture, and UV resistant
    • Ideal for cosmetic and high-end product packaging

    Polyester Foam

    Polyester foam is an open-cell, flexible polyurethane foam known for its fine texture, durability, and superior resistance to wear and tear. It offers excellent mechanical strength, making it ideal for applications that require repeated compression or consistent support. This material is commonly used in protective packaging, acoustic insulation, filtration systems, and cushioning for delicate instruments and electronics.

    Due to its open-cell structure, polyester foam provides excellent air permeability and sound absorption, which makes it a preferred choice for both industrial and commercial uses. It also maintains dimensional stability and resists deformation under stress, ensuring long-term performance.

    At Packaging Technology, polyester foam can be fabricated in various densities and thicknesses to meet your exact protection and design requirements. It can be easily die-cut, laminated, or shaped into custom inserts, providing a clean, professional presentation while ensuring superior product protection.

    Key Benefits:

    • Excellent strength and resilience for long-term use
    • Superior acoustic and thermal insulation properties
    • Smooth surface ideal for die-cutting and custom fabrication
    • Resistant to abrasion, chemicals, and environmental stress
    • Ideal for protective packaging, electronics, and precision components