High performance packaging

Plastazote packaging

High performance foam

Plastazote packaging

If you need to ship or protect very high-value, fragile, or business-critical items, Plastazote packaging provides the highest level of protection.

Plastazote foam is a cross-linked, closed-cell polyethylene foam. The material is water-resistant, provides excellent cushioning properties, and can be converted into intricate shapes and designs. Plastazote packaging typically takes the form of inserts for protective cases or boxes, handling trays, or dunnage for returnable containers.

At Suttons Performance Packaging, we can offer machined Plastazote inserts and other high-performance foam packaging for any protective or presentation application. As such, our Plastazote packaging provides exceptional product protection and a high-quality finish. Regardless of the product’s shape, size or application, we can design and manufacture a foam tray or insert that is a perfect fit for your product.

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Advantages

Benefits of Plastazote foam packaging

By using Plastazote foam packaging inserts at your business, you benefit from:

A precisely calculated level of cushioning protection.

Recesses that perfectly match the contours of your equipment or parts.

A durable, reusable and long-lasting foam solution.

A range of colours and grades, including two-tone shadow effect.

High-quality surface finishes.

Perfect compatibility with outer cases, boxes or containers.

Ultimately, the highest level of protection for your tools or products.

Plastazote foam experts

FAQs

Plastazote is a lightweight, cross-linked polyethylene foam. Its closed-cell structure, produced by injecting nitrogen gas into polyethylene, means it does not absorb moisture. It is ideal for high-performance packaging applications thanks to its durability and exceptional cushioning performance.

Plastazote has several applications specifically relating to packaging. These include high-performance case inserts that eliminate damage to your tools, inserts for corrugated packaging, dunnage for returnable packaging, and even stand-alone handling trays. A range of Plastazote machining methods also means it is suitable for retail display applications.

Plastazote is available in several grades. The manufacturer, Zotefoams, classifies these as either low-density (LD) or high-density (HD) grades. Plastazote packaging is also available in flame-retardant and conductive/static-dissipative options, as well as a wide range of colours.

A shadowboard is essentially a foam insert that uses two different colours of foam, usually with a dark colour on top of a brighter one. When this layered foam is routed or cut, the recesses show the brighter colour, which contrasts with the darker layer. As well as improving the aesthetics, this also helps to highlight where users have not returned tools or equipment to the foam/case.

Plastazote machining specialists

Why work with us?

We have extensive experience and expertise in converting a range of foam materials, including Plastazote, enabling your business to benefit in several ways.

Flexible volumes

As we convert in-house, we can manufacture your Plastazote packaging from a single unit up to many thousands.

Inventory management

Our large warehouse capacity allows us to store your bulky protective packaging at our site and deliver it to you as and when required, freeing up storage space at your business.

Expert design and prototyping

Our in-house designers have extensive knowledge of Plastazote, enabling innovative, commercially successful designs, prototyping, and sampling.

Knowledge

Our teams—from designers to customer services to production staff—have knowledge and understanding of the challenges faced by specific industries (aerospace, electronics, engineering, etc.).

Damage prevention

By analysing your products, tools or equipment, we can use specialist CAD software and theoretical testing to create Plastazote packaging with truly optimised performance.

Short lead times

Manufacturing in-house and using our own fleet of vehicles to deliver your packaging ensures we can offer short lead times and on-time deliveries.

Single source

You can source your Plastazote packaging alongside any outer packaging you need (protective cases, corrugated packaging, etc.), significantly improving fit and compatibility.

Product range

Whether you need single-trip cardboard boxes, tapes, labels, or high-performance multi-material packs, we can supply all your packaging, reducing costs and admin.

Wide range of options

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We can help with any form of Plastazote packaging your business needs—from protective case inserts to trays to tool control. Simply contact one of our experts for free quotes and unbiased advice.

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