Egg crate foam

Egg crate foam is an excellent option if you need to protect products of varying shapes and sizes during shipping.


Egg crate foam, also called convoluted foam, is widely used to line cardboard boxes and protective cases. Its surface features a repeating pattern of peaks and dips that resembles an egg crate. Typically made using polyurethane foam, it braces and cushions products, preventing damage.


At Suttons Performance Packaging, we have specialist equipment to create egg crate foam profiles. Combined with our other foam conversion and corrugated box manufacturing capability, we can develop a range of custom foam packaging products tailored to your products.

How it works

Egg crate foam is a simple yet effective way to protect items in transit. To use, simply follow these steps:

  • 1

    Assemble your corrugated packaging.

  • 2

    If your outer pack is not lined with egg crate foam, place a correctly sized sheet, profile side up, in the base.

  • 3

    Add the products you are shipping.

  • 4

    Place another sheet of egg crate foam, profile side down, over the products (this step is unnecessary if the carton's lid already has foam affixed).

  • 5

    Close the box. The foam condenses around the product(s), holding them in place during shipping.

  • 6

    Seal the box and ship.

Convoluted foam packaging

You can source convoluted foam sheets or egg crate foam packaging from us.


Our in-house manufacturing capability means we can supply sheets of material in the specific sizes your business needs or as part of fully fabricated foam packaging products.


Using a non-abrasive polyurethane foam, available in several grades, densities and thicknesses, egg crate foam stabilizes and cushions your products during transit, preventing damage. Unlike custom foam inserts, egg crate foam can accommodate products of varying sizes and shapes. It is also lightweight and cost effective.

We can supply your foam packaging, which includes end caps and anti-static options, as well as your outer packaging. This includes single-trip corrugated packaging, available plain or with print, and high-performance protective cases.

Why work with us?

With our own foam profiler at our conversion site in Cambridgeshire, plus a well-resourced design team, sourcing egg crate foam from us provides you with several benefits.

Flexible volumes

Our in-house manufacture, coupled with a material stock holding, allows us to supply both high-volume and low-volume foam packaging solutions.

Expert design and prototyping

Our team of designers can incorporate egg crate foam, lining and custom inserts into outer packaging, with prototypes available for testing as required.

Damage prevention

Combining design expertise, advanced software, and physical testing means we are confident your foam packaging will completely eliminate shipping damage.

Inventory management

If you have a regular, ongoing requirement for foam packaging, we can store it at our warehouse and supply it as part of a just-in-time agreement.

Knowledge

Besides extensive knowledge in foam engineering, our packaging experts have extensive knowledge of industries including IT, eCommerce, electronics, scientific, aerospace and more.

Single source

We allow you to source both foam and outer box or case together, reducing your admin, costs, and hassle (and improving compatibility).

Product range

Suttons Performance Packaging can be a single source supplier for all of your packaging requirements, including a wide range of tapes, labels, and other supplies.

On-time delivery

We understand the importance of getting your orders dispatched on time, so we maintain our delivery fleet to ensure you have your packaging when you need it.

Get in touch

If you use egg crate foam at your business, either as sheets or in assembled foam packaging, we are confident we can provide a more cost-effective, higher-quality solution (which we can tailor to your needs, too). Please get in touch for a free quote today.

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