What is the best type of foam for packaging? There are different materials used for packaging. The type that works best will depend on various factors, such as the nature of the product.

A report by the New York Post revealed that the number of damaged packages increased by a third in 2024. The most common packaging foam types are polyurethane and expanded polystyrene (EPS).

Let’s explore different types of foam used in packaging to help you find the best material.

Polyurethane Foam

Polyurethane is an open-cell structure foam that’s very soft and flexible. This type of foam offers excellent shock absorption and is ideal for packaging fragile and lightweight products.

Some of the features of polyurethane include:

  • Available in different densities depending on packaging needs
  • Resistant to abrasion and mildew
  • High durability

The cost of polyurethane is higher than that of other types of foam for packaging. Polyurethane is the custom packaging foam for electronic products. Its ability to absorb moisture also makes it perfect for packing items in boxes that may come in contact with water.

Expanded Polystyrene (EPS)

Considered the most affordable option, EPS has a rigid closed-cell structure. It can serve as protective packaging foam due to the following properties:

  • Capable of thermal insulation
  • Shock absorption
  • Lightweight and moldable into different shapes

EPS is also difficult to recycle. However, the non-biodegradable nature of EPS also gives it great durability. This type of foam is commonly used to pack food items and protect packaging for fragile items.

Polyethylene Foam

Polyethylene is one of the different foam types consisting of a closed-cell structure. This feature gives it greater rigidity and makes it more durable than polyurethane. Polyethylene also has excellent impact resistance, enhancing its ability to protect goods in transit.

Some of the characteristics of polyethylene are:

  • Moisture resistance
  • Flexible and comes in different densities
  • Non-abrasive and reusable

One of the packaging foam benefits of using polyethylene is its various applications, including packing medical devices and automotive products. But polyethylene does not have the same thermal insulation properties as polyurethane and EPS.

The price of polyethylene is slightly higher, but it’s worth it because it can be recycled. Recyclable packaging paper reduces the environmental burden of plastic waste.

Expanded Polypropylene (EPP)

Popular for its great strength-to-weight ratio, EPP is an excellent choice for protective packaging. You can enhance the safety of your product with box strapping when packaging with EPP. This type of foam is reusable and recyclable.

Cross-Linked Polyethylene (XLPE)

Cross-linked polyethylene is more durable than regular polyethylene. It also has superior resistance to temperature changes and chemical exposure.

The Environmental Protection Agency found that plastics generation in the U.S. has reached an all-time high at 35.7 million tons in 2018. Due to its durability, XLPE can reduce the need for more packaging material production.

Choose the Best Types of Foam for Packaging Today

Selecting the best types of foam for packaging can enhance customer satisfaction. Today’s online marketplace relies heavily on products reaching clients safely after purchase. Choosing the right material can meet your needs and grow your business.

Packaging Fulfillment Co. has over three decades of experience offering foam packaging solutions. We’ll leverage our expertise to provide innovative and customizable products that meet your needs.

Contact us today to learn more about our products and services.