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Specialist foam conversion to enhance the protection offered by your packaging
Foam conversion from Macfarlane Packaging can provide a wide range of protective foam packaging, including inserts, end caps and dunnage to maximise your product protection. Foam inserts are suitable for a range of applications. They are ideal for businesses looking to protect items during transit, enhance presentation for sales or end consumers, or organise equipment. At Macfarlane Packaging, we can offer foam packaging solutions that suit various applications, designed and manufactured by our specialist manufacturing division.
Designed to your specifications, foam inserts can be manufactured to match the contours of your products or equipment precisely. You can also select from a range of colours and material densities.
Choose from engineered inserts to single trip and more. We have the solution for you.
Explore our range of foam products
Engineered foam inserts
Engineered foam inserts
Engineered foam inserts for equipment and flight cases protect your tools, equipment, and products with precision.
Tailored to the shape and contours of your items, our inserts minimise movement within the case, ensuring safe transit without damage.
Custom foam inserts can also be designed using specialist software that calculates the optimum foam thickness, density and grade to eliminate damage almost entirely.
Foam end caps
Foam end caps
By efficiently utilising foam material, foam end caps provide excellent protection without excess weight or volume, reducing shipping costs and environmental footprint.
Manufactured to fit the end profiles of your items, these die-cut foam caps create a protective cushion, ensuring safe delivery. Paired with standard corrugated boxes, they offer a snug fit, minimising movement during transit. Experience the benefits of streamlined packaging, lower unit costs, reduced shipping expenses, and simplified recycling.
Foam-lined boxes
Foam-lined boxes
Unlike foam end caps tailored to specific items, foam-lined boxes accommodate various products, making them ideal for online retailers with ever-changing orders. The outer cardboard boxes are ideal for most eCommerce and postal applications, while the convoluted foam inside secures items in place, preventing movement during transit and minimising damage risks.
Not only do these boxes shield against shock, impact, and vibration, but the non-abrasive foam also protects product surfaces, ensuring your goods arrive in pristine condition.
Foam dunnage
Foam dunnage
These foam dividers and inserts streamline packing and unpacking processes in assembly lines and manufacturing environments, facilitating faster operations.
They also enable quick visual stock checks, preventing production from stopping due to parts shortages. Foam dunnage cam also prevent overloading, both protecting contents and ensuring safe handling.
Foam dividers optimise part transportation by maximising space within outer totes, reducing trips and enhancing efficiency.
Gift box foam
Gift box foam
Our gift box foam inserts are crafted from high-quality Plastazote® polyethylene foam to offer premium protection and presentation.
Advanced conversion processes ensure precise, smooth surfaces and sizes tailored to fit your cardboard gift boxes flawlessly.
Choose from a spectrum of vibrant colours to match your brand aesthetic, and personalise with laser-engraved logos for enhanced brand recognition.
Anti-static foam
Anti-static foam
Designed to dissipate electrostatic charges gradually, these foam inserts provide superior protection for static-sensitive components during transit.
Pink anti-static foam protects circuit boards, computer chips, and electronics from shock, impact, and vibration. Its use is commonplace in Corstat® and other anti-static packaging solutions.
FAQs about foam
What is foam conversion?
Foam conversion refers to the process of transforming raw foam material into practical products. While it encompasses various applications, such as upholstery and shoe insoles, it primarily pertains to manufacturing protective packaging, such as box or case inserts.
How is foam converted?
Foam conversion encompasses various methods, including die cutting, CNC routing, waterjet cutting, and laser cutting/engraving. In manufacturing protective packaging products, a combination of these processes is often employed to achieve the desired finished item.
Is there a difference between case foam and packaging foam?
Typically, Plastazote® is used for foam inserts for protective cases, including applications like tool control and shadow boards. In contrast, lower-cost foams like Stratocell are preferred for foam “packaging” due to their affordability, making them ideal for single-use applications. Plastazote® boasts a longer lifespan, ensuring durable long-term protection, while Stratocell offers cost-effective solutions for short-term needs.
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You can have foam conversion delivered to you from one of our regional distribution centres. UK delivery is available to and around the following locations:
Aberdeen, Aylesbury, Banbury, Barnsley, Bath, Bedford, Bicester, Birmingham , Bolton, Bradford, Bridgewater, Bridport, Bristol, Burton-upon-Trent , Cambridge, Chelmsford , Cheltenham, Chester , Chichester, Colchester Cornwall, Coventry, Crewe, Derby, Devon, Dewsbury, Dudley, Dundee, Durham, Edinburgh, Essex, Exeter, Fareham, Gateshead, Glasgow Glossop Gloucester, Grantham, Harlow, Heathrow, Hemel Hempstead, Hereford, High Wycombe, Horsham, Hull, Inverness, Isle of Wight, Kent, Kidderminster, Lancaster Leamington Spa, Leeds, Lincoln, Liverpool , London , Luton , Manchester, Middlesborough, Milton Keynes, Newbury, Newcastle-under-Lyme, Newcastle-upon-Tyne, Norfolk, North Wales , Northampton, Nottingham , Oldham, Oxford , Plymouth, Reading, Salisbury, Sheffield, Shrewsbury, Shrewsbury, Slough, Somerset , Somerton, South Shields, South Wales, Stafford, Stockport , Stoke-on-Trent , Stratford-Upon-Avon, Sudbury, Sunderland, Surrey, Sussex , Teesside, Telford, Uxbridge, Wakefield, Walsall, Warrington, Warwick , Watford, Wigan, Windsor, Wolverhampton, Worcester, Wrexham, Yeovil, York.
You can also have foam conversion from Macfarlane Packaging delivered across Ireland and Continental Europe. Click to find your closest UK location or nearest Continental European site.