Foam conversion will likely be vital if your business needs or uses high-performance packaging.
Foam conversion is the process of turning foam material into various products. Materials such as Stratocell and Plastazote are converted into products such as packaging, case inserts, and other consumer goods. Processes include CNC routing, die cutting, laminating, and welding.
At Suttons Protective 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.
We undertake several foam conversion processes at Suttons Performance Packaging in order to create your foam packaging.
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 end caps and similar Stratocell packaging.
Our computer-controlled CNC mill precisely cuts material away from the foam’s surface to create intricate 3-D 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.
Besides manual heat welding processes, we have also invested in automated heat welding equipment. The Fastweld equipment can quickly and accurately bond foam material using heat, improving the join quality and the manufacturing speed.
We use an in-house profiler to create egg crate or convoluted foam sheets. These sheets are often used to line boxes or cases, or can be supplied in sheet form.
Our computer-controlled saw allows accurate cutting of material ready for assembly or further fabrication.
Our CAD table can cut a wide range of materials, allowing us to produce pre-production samples for testing and appraisal.
Undertaking all of the foam conversion processes required to make your packaging in-house provides numerous benefits.
It allows us to completely control the quality of the foam packaging we produce. It allows us to produce both low and high volumes quickly and efficiently. It allows our in-house designers to maximise the potential of the available materials (including Stratocell, Plastazote, and Polyurethane foams).
And, combined with our corrugated packaging manufacturing capabilities, it allows you to source high performance, fully optimised assembled packaging from a single source.
Alongside packaging testing, at Suttons Performance Packaging we can offer a wide range of additional services to benefit your business.
If you would like advice on the best packaging for your application, a free quote, or further information, please contact one of our foam conversion specialists.