Polyethylene foam is primarily made by heating polyethylene plastic pellets mixed with a blowing agent. This mixture expands under controlled conditions, creating a cellular structure as it cools, typically through an extrusion process.

Understanding the basics is good, but how does it actually happen step-by-step? What specific materials go into it, and what different kinds exist? It's useful to know these details to make informed choices. Let's break down the raw materials, the production steps, how firm it feels, and compare it to similar foams like EPE. Stay with us to get a clearer picture of PE foam production.

What are the raw materials for polyethylene foam (PE Foam)?

Choosing materials feels complex, right? Wrong inputs mean poor foam quality and performance issues. We'll outline the essential ingredients for making reliable PE foam right here.

The main raw material is polyethylene (PE) resin, usually in pellet form. Key additives include a blowing agent (to create the cells) and sometimes cross-linking agents, colorants, or stabilizers depending on the final desired foam properties.

Let's look closer at what goes into making the PE foam we use at Foamtech. Everything starts with the base plastic:

• Polyethylene (PE) Resin: This is the foundation. It usually comes as small, solid pellets. We can use different types of PE, like Low-Density Polyethylene (LDPE) which makes softer, more flexible foam, or High-Density Polyethylene (HDPE) which results in stiffer foam. The choice depends entirely on what the foam needs to do.

• Blowing Agent: This is crucial for creating the foam structure. It's a substance that produces gas when the plastic is heated and processed. This gas creates tiny bubbles or cells within the plastic, expanding it into foam. Blowing agents can be chemical (decomposing to release gas) or physical (like injecting nitrogen or hydrocarbons).

• Cross-linking Agents (Optional but common): For certain types of PE foam, like the XPE and IXPE we often work with, special chemicals are added. These agents create strong chemical bonds between the polyethylene molecules during processing. This cross-linking makes the foam stronger, more heat resistant, and gives it a finer, more uniform cell structure.

• Other Additives: Depending on the application, we might add colorants for specific looks, UV stabilizers for outdoor use, or fire retardants to meet safety standards.
  Selecting the right combination of these raw materials is the first step in creating high-quality PE foam tailored for specific uses, whether it's protective packaging for David's industrial equipment or components for Sarah's PPE line.

How to produce PE foam?

Unclear about the manufacturing steps for PE foam? Misunderstanding the process hinders quality control and material selection. Let's walk through how PE foam is typically produced.

PE foam is mainly produced using an extrusion process. Polyethylene resin and additives are melted and mixed inside a machine called an extruder. A blowing agent creates gas bubbles, expanding the mixture as it exits the machine through a shaped opening (die). It is then cooled and formed into sheets, rolls, or planks.

Let me take you through the typical journey from plastic pellet to finished foam sheet or roll, as we often manage with our suppliers here at FoamTech. The most common method is extrusion.

1. Melting and Mixing: Solid PE resin pellets, along with any necessary additives like colorants or stabilizers, are fed into a long, heated barrel called an extruder. Inside, a rotating screw melts the plastic and mixes everything thoroughly into a hot, viscous liquid.

2. Injecting Blowing Agent: At a specific point in the extruder, the blowing agent¹ is introduced under high pressure. It dissolves or disperses into the molten plastic.

3. Extrusion and Expansion: The pressurized mixture is then forced through a shaped opening called a die. As the molten plastic exits the die, the pressure drops suddenly. This allows the dissolved blowing agent to turn into gas bubbles, rapidly expanding the plastic into a cellular foam structure. The shape of the die determines if the foam comes out as a flat sheet, a round profile, or another shape.

4. Cooling and Solidification: The newly formed foam immediately begins to cool, often using air or water. Cooling solidifies the plastic, trapping the bubbles and setting the foam's shape and structure.

5. Cross-linking (for XPE/IXPE): This is where specific types are made.

   • XPE (Chemical Cross-linked): For this type, chemical cross-linking² agents are added during the mixing stage. The heat in the extruder activates these chemicals, creating links between PE molecules before or during expansion. This is a common method in the China market.

   • IXPE (Irradiated Cross-linked): This process happens after the foam sheet is extruded and cooled. The solid foam sheet is passed under an electron beam (irradiation). This high energy creates the cross-links. IXPE generally has a smoother surface, finer cells, and better overall physical properties than XPE, but it's also more expensive. We find IXPE offers superior performance for many demanding applications.

Finally, the continuous foam sheet might be rolled up, cut into specific lengths, or undergo secondary processing like lamination or die-cutting, which are services we offer here at FoamTech.

Is polyethylene foam soft or hard?

Unsure if PE foam has the right feel for your product? Guessing can lead to materials that are too stiff or not protective enough. Let's clarify the typical firmness of PE foam.

Polyethylene foam is generally considered semi-rigid or firm compared to very soft foams like cushion-grade PU. However, its actual hardness varies a lot, ranging from relatively pliable to quite stiff, depending on its density and specific type.

When clients like Sarah ask if PE foam is soft enough for comfort layers in PPE, or when David needs assurance of its rigidity for industrial protection, I explain that "hardness" in PE foam isn't a single value. It exists on a spectrum. Compared to the squishy polyurethane foam in your sofa, most PE foam feels noticeably firmer and more resilient. It holds its shape better under pressure.
But within the PE foam family, there's significant variation:

• Density is Key: This is the biggest factor. Low-density PE foam (like some packaging grades or EPE) feels lighter and relatively softer or more flexible. High-density PE foam is much heavier, stiffer, and offers more resistance to compression. We specify density based on the required cushioning or support.

• Base Polymer Type³: Foam made from LDPE (Low-Density Polyethylene) resin tends to be more flexible than foam made from HDPE (High-Density Polyethylene) resin, even at similar densities.

• Cross-linking: Cross-linked PE foams (XPE and IXPE) generally feel firmer and more robust than non-cross-linked foams of the same density. The cross-linking improves the foam's structural integrity, making it spring back better after compression and feel more solid. IXPE, with its finer cell structure, often feels smoother and slightly firmer than XPE.

So, can PE foam be "soft"? Yes, relatively speaking, lower density grades can be quite flexible. Can it be "hard"? Absolutely, higher density and cross-linked types provide significant rigidity. We help select the precise grade to balance protection, support, and sometimes comfort, ensuring the foam meets the specific mechanical requirements of the application.

What is the difference between PE foam and EPE foam?

Confused by similar foam names like PE and EPE? This common confusion can easily lead to ordering the wrong material for your needs. Let's clearly define the difference.

EPE stands for Expanded Polyethylene foam. It is simply one specific type of PE foam. EPE typically refers to non-crosslinked, low-density polyethylene foam, often produced in plank or sheet form mainly for basic protective packaging applications due to its low cost.

This is a point of frequent confusion, so let's clear it up. Think of "PE foam" as the broad category name, like "fruit." EPE, which stands for Expanded Polyethylene⁴, is like a specific type of fruit, say, an "apple." So, all EPE is PE foam, but not all PE foam is EPE.
In practice, when people in the industry refer to "EPE," they usually mean a specific kind of PE foam characterized by:

• Non-crosslinked structure: Unlike XPE or IXPE, the polymer chains in EPE are not chemically bonded together.

• Low density: EPE is generally produced in lower density ranges compared to many other PE foam types.

• Manufacturing Process: Often made using physical blowing agents (like butane) injected during extrusion, resulting in a relatively coarse cell structure compared to IXPE.

• Common Form: Frequently supplied as thicker sheets or planks rather than thin rolls.

• Primary Use: Its main application is cost-effective protective packaging⁵ – think of the white foam blocks used to cushion electronics or furniture during shipping.

While EPE provides decent basic cushioning, its non-crosslinked nature means it's less durable, less resistant to heat, and has lower mechanical strength compared to XPE or IXPE foams. For applications requiring higher performance, better resilience, finer cell structure (for smoother surfaces), thermal forming capabilities, or greater longevity, we at FoamTech usually recommend moving beyond basic EPE to XPE, IXPE, or other specialized PE foam grades.

An important note on naming: Sometimes you'll see the term "XLPE" used. While this technically means "Cross-Linked Polyethylene" (which includes XPE and IXPE), be aware that in some international markets, "XLPE" is confusingly used to describe cross-linked EVA foam. Here in China, we are very specific: XPE and IXPE refer to cross-linked PE, while cross-linked EVA is identified separately. We always ensure clear communication about the exact material specification to avoid costly mistakes.

Conclusion

Polyethylene foam production involves heating and expanding PE resin with a blowing agent, often via extrusion. Understanding types like EPE, XPE, and IXPE helps select the best performance for your needs.

What is EPP foam?

EPP is one kind of closed cell foam material that requires a very precise and complex manufacturing process, with highly specialized custom-made equipment operated by seasoned professionals. The material can be shaped into many different formats and sizes, and molds are often used, depending on the desired outcome. The material is porous, consisting of several polypropylene beads. They let air pass through the beads, helping with acoustic insulation and weight reduction as well. Because of its versatility, it is highly sought-after in various industries, from constructions, to shipping, and more. EPP is an excellent and cost-effective material for thermal insulation, and its high buoyancy makes it resistant to water and other chemicals. If this wasn’t enough, EPP foam is also quite sturdy, and it is completely sustainable, since it can be recycled.

EPP is a popular material in the shipping industry, and it is meant to protect the contents of boxes and packages. In this application, it is often found in white. However, other colors are also common, particularly black, especially when it comes to industrial and automotive applications.

How is EPP (Expanded polypropylene) made?

EPP (Expanded polypropylene) is a remarkable material with many perks. It’s highly appreciated because of its light-weight, acoustic absorption properties, as well as thermal insulation, and sustainability. EPP is so widespread; it’s easy to forget that its manufacturing is a rather complex affair, requiring specialized tools and a lot of experience.

Facilities for the production of EPP are often outfitted with highly specialized instruments, measurement gear, and equipment, specifically designed for the purpose of EPP manufacturing and shaping. In fact, Expanded polypropylene can be shaped in many different formats, and it is also available in different colors, often depending on the specific industrial application.

EPP can be produced in great quantities, and it is usually considered more affordable than other materials with analogue properties, yet just as effective. EPP foam consists of polypropylene beads that are not packed together very densely. In fact, they allow some air space between the beats. This is great for acoustic insulation and thermal retention since they trap sound waves and air. In addition to that, the particular structure of the material also means that EPP is very light-weight. This is why it’s often used in the automotive industry when insulation is needed, without wanting to add extensive extra weight. EPP is also an excellent choice to protect items in boxes and packages, without adding too much additional weight.

Get to Know the Advantages of EPP Foam

EPP (Expanded polypropylene) is a multi-functional closed-cell bead foam that has a substantial number of uses and applications. It is lightweight, durable, and recyclable besides providing optimal energy management.

Some of the primary applications of EPP foam include:

• Industrial packaging
• Automotive parts
• Logistics and wrapping
• Shipbuilding
• Food preservation
• Waterproofing
• Lightweight constructions
• Furniture and design
• Suitable for a wide range of foam fabrication processes

The versatility of expanded polypropylene is the result of almost 50 years of research that has seen it become one of the most used products on the planet. Nowadays, EPP foam is heavily used in numerous manufacturing industries for its indisputable advantages, such as:

VIBRATION ABSORPTION

EPP foam comes in a broad range of densities that range from 15 to 200 grams per liter. Through molding, its density may increase to as much as 260 grams per liter. This impeccable density feature coupled with its high elasticity trait makes it ideal for insulating various environments against sound and vibration.

The polypropylene beads have a cylinder shape that allows for air to enter and remain in the space between them. As a result, even a thin layer of EPP foam provides reliable acoustical insulation. When used in thicker layers, this material becomes optimal for protecting rooms and vehicles from sounds and vibrations.

THERMAL INSULATION

EPP foam has a high thermal resistance that makes it perfect for insulation. This material is often used in the food industry to maintain foods and beverages in optimal conditions. Expanded polypropylene can keep most products at a stable temperature between that may range from -40 to +60 °С for a significant period.

Additionally, EPP foam prevents microbial growth and is often considered as a sterile medium for safe food packaging. By adding fire-retardant agents in its composition, EPP develops a low risk of flammability and high resistance to UV rays.

WATERPROOF AND BUOYANCY

One of the main advantages of EPP foam is its resistance to water. Even in conditions of high humidity, the material maintains its mechanical properties and ensures optimal water obstruction.
In addition, expanded polypropylene provides long-term buoyancy and as such, it is frequently used in the shipbuilding industry.

EPP foam cells are water-tight and almost impenetrable by other liquids and chemicals. This high-performance trait makes it an ideal material for waterproofing electrical appliances. It also recommends it for everyday use in isolating humidity-prone environments like bathrooms, saunas, and showers.
Since EPP foam is both waterproof and non-toxic, it is perfect for isolating potable water tanks, filters and other facilities where water quality standards need to be paramount.

UV AND OZONE RESISTANCE

Last, but not least, EPP foam has a high-resistance to UV rays. Its unique construction recommends it for outdoor insulation especially in areas that are heavily exposed to harsh weather and other environmental stresses.

Expanded polypropylene is suitable for geographical areas where the ozone layer is thin and where UV rays can affect entire communities of people. This safe and eco-friendly foam is perfect for protecting the environment against radiation, degradation, and abrasion.

Application of EPP (Expanded Polypropylene) Foam

One of the most versatile parts is EPP foam. These foam beads can be placed in molds, allowing them to form multiple shapes. Though you might not have heard of it, it can be used in a range of situations. Let’s look at some of the most common applications for this foam.

Automotive Industry

One of the most common places to use EPP is in the automotive industry. There are multiple reasons why EPP has become so widely used in this industry. For example, car manufacturers appreciate how durable and functional it is. For this reason, EPP can be found in multiple products. Some common examples might include; door panels, headrests, sun visors, bumpers, and seats. It can also be used to construct multiple other parts.

Packaging

Another popular way to use EPP is to make packaging. Distributors are always looking for ways to make sure that delicate items get to their customers safely. For this reason, they frequently choose to use EPP foam. There are multiple reasons why they do this. First, this foam is very lightweight. This means that it doesn’t cost much to ship. Also, it has high shock absorption. This ensures that it will provide adequate protection for items that are accidentally dropped. Finally, because they don’t need high-quality EPP for packaging, they can purchase this material cheaply.

Industrial Products

Increasingly, industries are looking for ways to offer high-quality prices at lower costs. They can do this by using EPP foam. This product is lightweight and can easily be cut into various shapes. It’s very durable, helping industrial products last for a long time and provide good value for money. They can also absorb the energy from an impact. For this reason, they can be used to create a safer work environment, providing protection if something goes wrong. Finally, products made with EPP are very strong. This means it can take a large strain before it breaks.

Consumer Goods

EPP is used to create a range of consumer products. There are a few simple reasons for this. First, it is lightweight. This ensures that products made from EPP will be easy to ship. Also, the foam can be easily molded into a wide range of shapes. Manufacturers can also color EPP, this makes it perfect for creating products like colorful children’s toys. Finally, EPP is anti-microbial. This makes it perfect for making products like food coolers, reducing the chances that people will get diseases from using the container. Because of these benefits, there are multiple consumer products that are made from EPP. Some common examples include; furniture, model aircraft, floor levelers and shelving units.

One of the most important substances is EPP foam. As we’ve seen, it can be found in a wide range of products across multiple industries. This is because of a range of unique qualities that this substance possesses. Hopefully, you now have a better understanding of what EPP foam is and how it might be used.

You might not know what the brush material is. But currently EVA foam is largely used as auto car wash brush for the washing equipment. Check it out next time when you will be there.

Here in this post, we are going to introduce you how EVA foam brush works in automobile washing systems.

Links between EVA foam and Car Wash Systems

When you get a close check of car wash equipment and systems, you could find out hundreds of EVA foam brushes neatly assembled on a rotatable metal shaft as a powerful washing parts.

At first, you may not know what is EVA foam? Not to worry, here is a quick link to get full information of this versatile material – EVA foam.

Briefly EVA foam is closed cell foam varying in a wide range of densities and hardness. Importantly, you should note that, different density and hardness can make a EVA foam with a quite difference performance and property. So choosing a EVA foam with proper performance for car wash equipment seems to be very important.

Brush is a very important part of automatic car wash equipment system. It is apparently simple to know that brush is the essential part used to clean up car or other vehicles. As auto wash brush, EVA foam is needed to be wear-resisting and highly durable which are rotated vertically or horizontally to thoroughly wash car or other vehicles. Also for a auto car washing machine, the attached foam brush is a frequently used accessory for every day operation.

Currently car wash equipment company mainly use EVA foam brushes, traditional plastic bristle brushes, cloth textile material brushes. Among them, due to the advantages on both performance and costing, EVA foam has been more and more frequently used for auto car wash brushes.

Get to know why EVA foam can be idea fit for car wash system

Based on EVA foam properties, we will illustrate why EVA foam brush is a good choice for car washing systems.

• Water Resistant

As mentioned, EVA foam material is a closed cell plastic material with low water absorption. They are naturally waterproof material because of their closed foam structure. On the contrary, open cell foam is week facing with water, moisture or other liquid. For more, you could find out difference between closed cell foam and open cell foam from this link.

Working as auto car wash brush, waterproof EVA foam can largely save water used for cleaning. Their cleaning performance is not affected by water flow when operation. Besides, EVA foam car wash brushes also do not hold dirt when working on vehicles.

• Chemical Resistant

Due to closed foam structure, EVA foam has excellent performance on solvent resistance. You can easily know that when your car is served at a car washing station. Relevant detergents would should be used to facilitate this process. EVA foam are good at working with washing chemicals. They will be be affected by all sorts of detergents and keep excellent washing power.

But when using textile wash brush, you will clearly find out that they will inevitably absorb and keep water on itself. So sometimes textile cloth brush could not clean up thoroughly and leave some dirty spot on cars.

• Abrasion Resistant

Car wash brush is an import auto car washing system accessory, which is used every day for car washing. In actual operation, foam brushes will be rotating along with washing machine to remove dirt on vehicles. This process is a constant process which can abrade brushes every time with strong impact force. So foam brushes have to be highly resistant to that daily abrasion.

When working, foam brushes would go through almost every aspect of car body, windshield other wheels etc. But the underlying fact is regular EVA foam can not withstand such suffering process in the long time. Only specialized EVA foam brush can make this, and perform well also in long term run.

Specialized EVA foam can be with excellent tensile strength and elongation performance. Those properties are needed to a nice car washing brushes.

• Soft and Cushioning

With flexible and adjustable hardness, EVA foam can be formulated to be soft and resilient. It is a quite versatile foam material with good impact absorption ability.

Car washing is needed to be very careful as any harsh operation might cause problem for customers’s car. As a car wash brush, it can not be made by hard or rigid material. Soft EVA foam brush can deliver a reliable, safe and gentle service for vehicles. They are resilient and cushioning, which can provide a consistent shockproof performance.

Additionally, when working on the tunnel car wash systems, auto car wash brushes will be stretched by rotating shaft at a constant and high speed. Soft and resilient EVA foam is ideally able to sustain this process.

• Various Colors, Sizes, and Shapes

We believe people want to see more colorful things not just a black or white. EVA foam can be flexibly made in various custom colors. They are naturally colorful, and are available in a lot of color ranges including red, yellow, blue, orange, green, gray and so much more.

With auto car wash brush, your car washing equipment can be colorfully decorated. It is refreshing for both your marketing work and attractive to your customers.

Automatic tunnel car washing systems is a complicated integration which are designed to wash almost every part of the vehicle. EVA foam can be a great fit to get this work done. They comes originally as a large bun, but can be made by many foam fabrication techniques into any custom sizes and shapes.

With this advantage, EVA foam are made into various car wash brushed with different sizes and shapes. They can function and work for cleaning of different part of a car.

Analysis of 5 Top Companies in Car Wash System Industry

Here let us take a look at 5 top players in car wash equipment markets. The 5 top companies has been innovating and leading car wash systems and equipment. Today we will take you a way to see how they work with EVA foam as car wash brush.

They are Istobal from Spain,  WashTec from Germany, Tommy Car Wash Systems and NS Wash Systems from USA and MacNeil from Canada.

Case #1 Istobal has been releasing their latest and innovation car wash brush fitting system. This new system can allow machine users only change worn brush material, and save cost on fitting system. It is a simple, easy but powerful system with patent obtained. Their fitting system is patented, but you have full access to EVA foam as auto car wash brush.  You can change the worn foam brush with new foam brush from other supplier.

Case #2 High performance EVA foam is also utilized by WasTec, which is also a global leader in car wash systems. Their revolutionary washing materials – SofTecs is actually a kind of superior EVA foam material. As they mentioned, SofTecs is created from a non-porous material and is guaranteed to be the safest way to wash vehicles. This is just what high quality EVA foam can do!

Case #3 After checking the marketing information on website of Tommy Car Wash Systems, we can clearly see that they are using a lot of EVA foam brush as wrap brush, top brush, and side brush for their washing systems and parts. Red and gray color are the featured color for car wash brushes of Tommy Car Wash Systems. EVA foam car wash brushes are gentle soft foam, and can offer a closer and more thorough wash. This can actually make washed car shine than before.

Case #4 The after checking the information about NS Wash Systems, we found out that what they use for wash brush materials is very similar with Tommy Car Wash Systems. N/S Corporation has used EVA foam their primary washing material, and they each have a category for foam wash brushes. The EVA foam brushes work for their rocker panel brush, top brush and wrap brush. NS Wash Systems has expanded the capability to design car wash systems not just for car wash, but for special project like transit, bus and so on.

Case #5 Auto car wash brush is one of the most important equipment for MacNeil car wash systems. hey have branded their foam brushes as Envirosoft®. They have been declaring that Envirosoft is a kind of long-lasting foam, and can bring a sparkling and safe finish, which is available in a variety of attractive colors and patterns. It is actually just a kind of high performance EVA foam sheet.

Conclusion on Using Auto Car Wash Brush

High performance EVA foam are widely used as car wash brushes by lots of tunnel car wash systems providers. They are vital washing material for car wash machinery. They are quite flexible to be made in a wide range of custom shapes, sizes and properties.

Also please do not forget the emphasis is on high performance EVA foam. Regular EVA foam material can not deliver excellent performance during working on automatic car wash equipment, and they can not go through rotation process in the long term run.

It deserves to invent in specialized EVA foam with higher cost than regular EVA foam, and they will pay you off in every day operation.

So what high performance EVA foam is good at? Based on our vast experience working with car washing systems provider and end customers, car wash foam brush should be excellent at tensile strength, elongation rate, abrasion strength and tearing strength. This guides to make sure before you choose a EVA foam material as your foam brushes.

For more detail on your custom case about EVA foam auto car wash brush, please feel free to contact us at info@www.foamtechchina.com. Your inquiry will be responded from our most professional service!

Here we are going to illustrate some common foam packaging types, so it can be much instructive for you to choose the right foam packaging solution for new products. The most frequently used foam material for protective packaging include EVA foam, EPE foam, PU foam, Cross-linked PE foam ( XPE foam & IXPE foam), EPS foam ect.. Also some of those foam materials can be possessed of enhanced properties by utilizing different fabrication techniques.

When you are in face of all these foam materials for a packaging solution, it could be evidently bewildering. Let's go forward and learn more about them.

EVA Foam Packaging & EVA Foam Insert

Remember! When you are considering a foam packaging design, EVA foam could be your No.1 option!

EVA foam material is offered in various densities and colors, and this makes it a very common and popular foam material for custom foam packaging insert. For heavy products, we can use high density EVA foam sheets to fabricate custom foam inserts. High density EVA foam insert can provide better tensile strength and protective supporting for heavy goods. On the other hand, medium density and low-density EVA foam can be much suitable for products with light weight.

EVA Foam Insert - Feature & Benefit

EVA foam sheets are available in multiple colors and can be manufactured in even any colors within PMS color chart.

• Moisture, Water, Heat and Oil resistance

EVA foam are typically closed cell foam material which is good at resistance of moisture, water, heat, oil and other fluid. Those properties are vital for keeping and transporting your precious goods. By using EVA foam material, you will not have to worry kept products being affected by moisture and water. Also You could always find EVA foam used in many foam packaging products like EVA foam insert box, Jewelry foam insert, gift box foam insert, foam insert for tool box and so on.

• Consistent Cushioning Protection

As mentioned before, EVA foam is available in a wide range of densities from 33 kg/m³ to around 280 kg/m³. They are suitable for packing various weight of products by using different density foam. EVA foam insert is generally flexible and cushioning compared with hard and solid plastic material. EVA foam cut out packaging can provide excellent cushion protection for products kept within foam inserts.

• Easily Work With Various Foam Fabrication Processes

EVA foam can be fabricated by various fabrication techniques including custom steel die-cutting, compression punching, PSA lamination, CNC contouring cutting, hot wire cutting, foam thermoforming and so on. All these techniques can be quite helpful to achieve custom required foam packaging solutions such as foam pick and pluck, foam insert with holes and EVA foam cut out.

• Easily Work With Custom Printing

When you consider having custom printed foam packaging, EVA foam could be a right choice. Compared with cross-linked polyethylene foam or PU foam, EVA foam has a smooth surface which makes it quite suitable for custom printing requirements.

• Available In Various Colors For Better Product Presentation

EVA foam materials are molded foam buns and can be provided in a wide range of colors. When you are considering releasing a new product, colorful EVA foam insert can help provide impressive and professional product presentation. They can be made for a foam insert box in 2 or more different colors and could be more eye-catching.

• Laminated Velvet Available For Luxury Foam Insert

For some particular items like luxury goods, sometimes they indeed need foam cushioning insert for protection. They also have strict aesthetics requirements for product presentation. EVA foam packaging can be designed with soft and touchable velvet or felt. Velvet foam insert and foam insert tray are perfect to use for gift box, jewelry box, watch box and so on.

EVA Foam Insert - Difference From Other Foam Packaging

The EVA foam has smooth surface and is available in various colors including white, black, blue, red, gray, yellow etc.. They are also offered in various densities normally from 33 kg/m³ to around 280 kg/m³ in different firmness from 15 shore C to 80 shore C. They are suitable for most of general purpose foam packaging including foam case insert, EVA velvet foam insert, EVA tool box foam insert.

EPE Foam Insert - Low Cost Foam Packaging Solution

Expanded Polyethylene Foam also know EPE foam has been a very economical foam packaging material. Besides being made as EPE foam packaging, they are also working as foam packing sheet for cushioning protection. Considering this, they are the most basic foam packaging products.You could find EPE foam in many packaging applications. White color is the standard color for EPE foam sheet that are frequently used as foam packing material. They could also be in black and pink color. Also you could note that pink EPE foam always has anti-static property. The pink color can make them stand out from standard white or black EPE foam.

EPE Foam Insert - Feature & Benefit

• Stable Foam Density and Lightweight

EPE foam material has consistent foam density ranging from 23 kg/m³ to 28 kg/m³. They are lightweight and cushioning foam material. This can be a good advantage that EPE foam packaging can save the total weight of cargo for shipment.

• Moisture and Water Resistance

Expanded Polyethylene foam has closed cell foam structure and they are non cross-linked Polyethylene foam. You could find them for applications such as floor underlay, foam packing sheet. When EPE foam used for foam packaging, they can also perform well on moisture and water resistance.

• Shock Absorption and Heat Insulation

Compared with EVA foam, EPE foam packaging can not outperform on durability. But EPE foam insert can perform better on heat resistance than EVA foam. They can also offer good basic impact absorption performance. EPE foam cut out packaging can ensure lightweight products safely for shipment.

• Low Cost Foam Packaging Solution

EPE foam could be the most cost-effective custom foam packaging material. They are low cost material and can provide basic also workable cushioning protection for production. When your priority is not aesthetics for foam inserts, EPE foam cutout packaging might be a good choice.

EPE Foam Packaging – Difference From Other Foam Packaging

EPE foam packaging do not present a smooth surface like EVA foam or XLPE foam. They has an uneven and rough appearance. They are low cost foam packaging material with odor free. Also they have good performance on heat insulation and moisture resistance. EPE foam can be cut to size as customer requests which is popularly used for goods shipment and storage.

PU Foam Insert - Soft & Flexible Open Cell Foam Packaging

PU foam short for polyurethane foam is a kind of open cell foam material. Polyurethane foam are lightweight which is widely used in consumer goods such as bedding, furniture, carpet underlay and so on. Polyurethane foam has a wide range of densities. We usually use PU foam of density from 12 kg/m³ to 60 kg/m³ for PU foam packaging insert.

PU Foam Packaging - Feature & Benefit

• Lightweight and Soft

The PU foam material used for foam packaging is often lightweight, flexible and soft. It is open cell polyurethane foam. They could not compete with closed cell foam such as EVA foam and Polyethylene foam on water & moisture resistance. But they are good at resilience and that is why they can be the main material for sofa or furniture upholstery.

• Excellent Noise Reduction

As mentioned, PU foam used for cushion packaging is open cell material. They are excellent at noise reduction and can be custom convoluted as egg crate convoluted foam. They can be used for many acoustic required places such as recording studio and conference room etc..

• Flexibility, Resilience, Shock Absorbing

Like other foam materials, Polyurethane foam is also flexible and resilient. Foam case insert made by PU foam can be good at shock absorbing. Also PU foam is usually used for packing lightweight items in small gift boxes or cases.

• Pick and Pluck Foam

Do not forget you could see PU foam mostly used for pick and pluck foam packaging which is a quick and convenient foam insert that can be available for DIY.

• Anti-static, fire retardant also various densities available

PU foam packaging can also be made with anti-static function by simply using anti-static PU foam material. They are quite suitable for packing special or precious electronics or metal instruments. Just like EVA foam, open cell Polyurethane foam is available in a wide range of density and can be a nice benefit for various custom applications.

PU Foam Packaging – Difference From Other Foam Packaging

PU foam has a unsmooth surface and you could find clear foam cell on all sides. They can be provided in a wide range of densities. PU foam inserts are resilient and flexible. They are good at sound reduction and shock absorption. But they are not resistant to moisture, water, oil and other fluid. Regarding production cost, they are usually more economical for foam packaging compared with PE foam and EVA foam.

Cross-linked Polyethylene Foam Packaging

Crosslinked Polyethylene foam is also a very popular choice for foam protective packaging. They are durable, strong and resilient which can be used for lots of industries including packaging, transportation, automotive, construction and so on. Polyethylene foam family includes EPE (Expanded Polyethylene) foam, XPE ( Cross-linked Polyethylene)foam and IXPE ( Irradiation Cross-linked Polyethylene ) foam also known as XLPE foam. EPE foam is non cross-linked foam material as we have already illustrated above, and the rest two are cross-linked foam.

Here we are introducing the rest of 2 kinds Polyethylene foam - XPE foam and XLPE foam which are higher quality PE foam. They can performs better on moisture resistance, heat insulation, vibration dampening and durability etc.. XPE foam and XLPE foam are both cross linked foam materials and can be provided in a wide range from 30 kg/m³ to 300 kg/m³. Polyethylene foam with density from 30 kg/m³ to 50 kg/m³ is mostly suitable for using as protective foam packaging. Compared with XPE foam, XLPE foam also short for IXPE foam can function better than XPE foam and can be used for medical applications and superior floor underlay.

Crosslinked PE Foam Insert - Feature & Benefit

• Premium Heat Insulation Performance

Work as custom foam packaging, PE foam can deliver excellent thermal insulation performance. You can find PE foam material used in many heat insulation required applications such as wood floor underlay, Polyethylene foam tapes, roofing construction and so on. Both crosslinked Polyethylene foam and irradiation cross linked Polyethylene (XLPE) foam can be excellent at heat insulation.

• Closed Cell Foam For Superior Moisture Resistance

Polyethylene foam is of closed cell foam structure which result in ultra low water absorption rate. PE foam packaging has the same properties and have superior performance on water & moisture resistance. Once your products placed in Polyethylene foam case insert, they can just be safe and sound for shipment and product presentation.

• Long-term Durability and Cushioning

Another excellent benefit for PE foam packaging is its long term durability. Both XPE foam and IXPE foam have premium properties at tensile strength, elongation and compression recovery abilities. PE foam have ideal resistance ability against moisture, oil and acid etc.. Custom polyethylene foam insert can protect your products with long term cushioning.

• Ideal Shock Absorption

Just like other foam packaging, PE foam packaging are cushioning and flexible. Both cross-linked Polyethylene foam packaging and irradiation polyethylene foam insert can offer excellent vibration dampening for your products. They can effectively shelter precious goods from vibration and shock during transportation.

• Available in various colors, densities and easy to be custom fabricated

Same like EVA foam, Polyethylene foam can be offered by foam suppliers in various colors and densities. Black and white are the standard colors but other color such as red, green, blue also custom available. Regarding foam densities, both XPE foam and IXPE foam have a wide range of densities choice. They can tailor made to meet various customers' needs. Also PE foam can be easily working with all sort of foam fabrication processes including die-cutting, foam lamination, CNC contouring cutting, foam thermoforming and so on.

Crosslinked Polyethylene Foam Insert – Difference From Other Foam Packaging

Chemically Crosslinked PE foam material has an unsmooth outside surface. XLPE foam has a smoother surface and better technical properties compared with XPE foam. Both of them have excellent properties on moisture resistance, durability, resilience and heat insulation. They are excellent to be as foam packaging insert for industrial instruments and electronics. They can be available in a wide range of colors and densities from 30 kg/m³ to 300 kg/m³.

Hope all above information can be informative and directive for you to choose your best foam packaging insert. For more question and idea, please contact us at info@www.foamtechchina.com.