Service and support

Foam conversion

Foam conversion will likely be vital if your business needs or uses high-performance packaging.

Foam conversion is the process of turning foam materials into various products. Materials like Stratocell® and Plastazote® are converted into products such as packaging, case inserts, and other consumers goods. Processes include CNC routing, die-cutting, laminating, and welding.

At Suttons Performance Packaging, we have extensive foam conversion capabilities. This includes a design team with specific knowledge of foam materials, high-tech equipment, and a clean, modern production site. This allows us to create foam packaging optimised for your specific products and applications.

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Foam conversion

Foam conversion processes

We undertake several foam conversion processes at Suttons Performance Packaging in order to create your foam packaging.

Die cutting

Die cutting involves using a tool (die) to cut foam into different shapes. This is a quick and cost-effective way to manufacture both simple and relatively complex shapes. We have several die cutters for manufacturing foam end caps and similar Stratocell® packaging.

CNC routing

Our computer-controlled CNC mill precisely cuts material away from the foam’s surface to create intricate 3D recesses and profiles. The profiles can be an exact match for the product you are placing into the foam. This process is typically used for creating Plastazote® packaging and protective case inserts.

Heat welder

Besides manual heat welding processes, we have also invested in automated heat welding equipment. The Fastweld equipment can quickly and accurately bond foam materials using heat, improving the join quality and the manufacturing speed.

Profiler

We use an in-house profiler to create egg crate foam or convoluted foam sheets. These sheets are often used to line boxes or cases, or can be supplied in sheet form.

CAD table

Our CAD table can cut a wide range of materials, allowing us to produce pre-production samples for testing and appraisal.

CNC sawing

Our computer-controlled saw allows accurate cutting of material ready for assembly or further fabrication.

Advantages

Benefits of our foam conversion service

Using our foam conversion service, your business could benefit from:

High-performance protective foam designed around your products.

Precise product fit with accurate CNC routing and profiling.

Flexible production volumes from low to high quantities.

Consistent quality with foam conversion completed in-house.

Faster production with modern equipment and automated processes.

Reduced material waste by optimising foam for each application.

Complete packaging solutions all from one supplier.

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FAQs

Foam conversion is used to turn specialist foam materials into protective packaging components such as case inserts, foam end caps, box liners, and bespoke product interiors. The foam can be shaped to closely match your product, providing, cushioning and protection during handling and transit.

We can convert a range of specialist foams, including Stratocell®, Plastazote®, polyurethane and recycled foams. Our team can recommend the most suitable material and conversion process based on your product, application and required level of protection.

Our in-house capabilities include CNC routing, die cutting, heat welding, profiling, CNC sawing and CAD cutting. This allows us to produce everything from simple protective components to complex 3D foam inserts.

Yes, our foam conversion and corrugated packaging manufacturing capabilities allow us to create complete packaging solutions from a single supplier. For example, we can manufacture a corrugated box with bespoke foam inserts designed to hold and protect your product securely.

Competitive advantage

Why work with us?

Put simply, by working with us at Suttons Performance Packaging, you can expect a wealth of experience and benefits that directly impact the success of your operations:

Flexible volumes

We can produce foam components in a range of volumes, from smaller production runs through to larger ongoing requirements.

Bespoke manufacturing

Our in-house conversion facilities allow us to manufacture foam components to your exact size, shape and specification.

Expert design and prototyping

Our experienced designers can develop and prototype foam solutions tailored to your products, materials and application.

Industry knowledge

We have extensive experience providing foam packaging solutions for IT, medical, aerospace, automotive, precision engineering and manufacturing applications.

Product protection

Our foam conversion capabilities allow us to create precisely shaped components that provide reliable protection during handling, storage and transit.

UK-wide delivery

With our own delivery fleet and UK-wide warehousing network, we can provide reliable foam packaging deliveries wherever your business is based.

Quality assured

Our in-house foam conversion processes give us greater control over the quality, consistency and performance of your finished products.

Dedicated support

Our designers, product advisers, production and customer service teams work together to support you from initial requirements through to manufacture and delivery.

Wide range of options

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If your business needs protective packaging, we offer a range of cost-effective, stock or bespoke options that provide a tailored level of performance. Please get in touch to find out more and request a free quote.

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