Convoluted foam packaging

Egg crate foam

Convoluted foam packaging

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 packaging, 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 from polyurethane foam, it braces and cushions products, helping prevent damage.

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

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Process

How it works

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

Assemble your corrugated packaging.

If your outer pack does not already have a convoluted foam lining, place a correctly sized sheet, profile side up, in the base.

Add the products you are shipping.

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).

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

Seal the box and ship.

Advantages

Benefits of egg crate foam

By using egg crate foam at your business, you benefit from:

A versatile packaging solution suitable for a range of products.

Low-cost solution for single-trip packs.

Quick and easy packing for fulfilment staff.

Range of material options, including recycled foams.

Effective cushioning protection for delicate and expensive items.

Ability to source convoluted foam and outer boxes together.

Reusability over multiple shipments.

Egg crate foam experts

FAQs

Egg box 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.

There are several alternatives to convoluted foam padding in modern manufacturing. If you consistently ship the same products (rather than differing shapes and sizes) there are other foam packaging options available, These include foam end caps and custom foam inserts, both of which can provide a bespoke level of protection and reduce material use.

Egg crate foam uses a non-abrasive polyurethane foam, available in several grades, densities and thicknesses. This material is typically softer than Stratocell and other polyethylene foams, making suitable for this application.

A special profiler is required to manufacture egg crate foam. The material is passed through the machine, which shapes it to the convulted pattern. This sheet is then cut to fit corrugated boxes, cases, or other packaging as required.

Convoluted packing foam manufacturers

Why work with us?

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

Flexible volumes

Our in-house manufacturing, coupled with material stockholding, allows us to supply both high-volume and low-volume foam packaging solutions.

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.

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.

Knowledge

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

Damage prevention

Combining design expertise, advanced software, and physical testing gives us confidence that your foam packaging will completely eliminate shipping damage.

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.

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.

Wide range of options

Similar foam packaging

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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).

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