A detailed guide to Plastazote® foam

Have you heard of Plastazote® foam before? Or perhaps you’ve come across the advantages of foam packaging and how it helps protect products from damage during transit. If not, it’s time to learn how foam can protect your products, equipment, and supply chain, ultimately helping you avoid costly damages.

Consistently delivering damaged products or parts to customers can have significant consequences. Returns, write-offs, lost productivity, and a damaged reputation are just a few of the adverse outcomes of inadequate packaging. Therefore, understanding foam solutions like Plastazote® packaging could solve your packaging and protection challenges.

1. What is Plastazote® foam?
2. How is Plastazote® manufactured?
3. Key benefits of Plastazote® foam
4. Applications for Plastazote® foam
5. Plastazote® in action
6. Summary

Plastazote® is a brand of closed-cell, cross-linked foam manufactured by Zotefoams®, part of their AZOTE® foam family. It’s widely recognised as the industry standard for high-performance foam, especially in packaging applications.

Plastazote® foam is made from nitrogen cells embedded in a polyethylene matrix, which gives it several key properties. The foam is closed cell, meaning the nitrogen cells don’t connect, which prevents the absorption of liquids and gases – a crucial feature for specific packaging needs.

Lightweight, non-toxic, and highly durable, Plastazote® is resistant to most oils, solvents, avids, and alkalis. It’s weatherproof, UV stable, and easily washable or disinfected. However, perhaps the most crucial feature for packaging is its ability to absorb energy during impact. Each cell in the foam acts like a balloon, compressing and recovering to its original shape, making Plastazote®  ideal for shock-absorbing packaging.

Plastazote®  foam is created by injecting nitrogen into polyethylene, causing the material to expand. Its versatility in fabrication makes Plastazote®  particularly useful for packaging.

It can be easily cut, routed, or shaped using CNC machinery, saws, water jet cutting, and other foam conversion techniques. Plastazote® can also be bonded to various materials like fabrics, metals, plastics, and wood, making it a perfect choice for custom inserts in packaging.

The foam’s cross-linked structure allows it to be thermoformed at low temperatures through compression or vacuum moulding. This makes it highly adaptable, allowing manufacturers to create details and protective profiles for delicate or valuable items.

With specialised software, companies can even design foam inserts tailored for specific compression and drop test data, ensuring that products are fully protected during transit.

Plastazote® foam offers numerous benefits that make it one of the most versatile and reliable materials for packaging, including:

• Lightweight and durable.
• Effective impact absorption.
• Consistent cell size for uniform production.
• Wide range of densities and colours.
• Water repellent and buoyant.
• Chemical and UV resistant.
• Thermal insulation.
• Non-toxic and safe for handling.
• Easy to work with and shape.
• Non-staining and low odour.

The actual value of Plastazote® foam lies in its wide range of applications. Beyond its versatility, it spans numerous industries, making it a reliable choice for various protection needs.

Here are some of the primary uses for Plastazote® foam:

• Protective case inserts: Custom foam inserts are perfect for securing products, tools, and equipment during shipping, reducing the risk of damage.
• Tool control: Foam inserts allow you to organise and track tools, preventing loss and improving operational efficiency.
• Cushion packaging: Whether moulded or machined, Plastazote® foam provides reliable cushioning for delicate items, absorbing shocks and impacts during transit.
• Dunnage and returnable packaging: Foam inserts and pads ensure that items stay in place during transit, even in multi-use containers like totes and creates.
• Electronics packaging: Antistatic grades of Plastazote® help protect electronic devices from the damaging effects of electrostatic discharge (ESD).
• Medical and military packaging: Plastazote®  meets the demanding requirements of military and medical packaging, offering sterile, shock-resistant solutions for sensitive equipment.

Protective case foam inserts

Plastazote® is widely used for custom foam inserts in protective cases, providing a reliable cushioning solution for high-value items, tools, and sensitive equipment. The foam’s shock-absorbing qualities ensure that products stay safe throughout transit.

Shadow foam and tool control

Custom foam inserts with contrasting colours (shadow foam) help track tools in industries like aerospace and automotive. This prevents tools from being misplaced, improving productivity and minimising costs associated with lost or forgotten equipment.

Cushion packaging

When used as cushion packaging, Plastazote® can absorb shock and vibration, keeping products secure and safe during transit while protecting delicate surfaces from scratches.

Dunnage and returnable packaging

With specialised anti-static grades, Plastazote® is perfect for packaging electronic components sensitive to electrostatic discharge (ESD), preventing costly damage during shipping.

If your business handles fragile or sensitive equipment, Plastazote® foam is a protective solution. Its range of benefits, including impact resistance, durability, and customisation options, makes it an excellent choice for various industries, from packaging to military and medical applications.

Using Plastazote® foam inserts, dunnage, and other solutions can reduce damage, improve organisation, and provide better protection for your high-value products during transit and storage.