How did the foam insert revolutionize packing and shipping? From the time Otto Bayer and other inventors invented Polyurethane in the late 1930s, polyurethane had been widely used as upholstery, insulation for buildings, as well as packing and shipping. Boxes provide product protection by themselves but often require inner components to cushion fragile contents. To eliminate breakage, the fragile items need to be cushioned by softness keeping the products intact. It also needs to absorb shock and pressure and hence, foam inserts is a natural part of the packing and shipping industry.
Foam inserts made of polyurethane foam is a perfectly ideal shipping insert because the material itself is so soft. Simultaneously, the same soft foam insert material is an outstanding shock absorber, perfect for protecting even the most fragile item. Foam inserts are light weight, perfect for reducing shipping cost. It’s the best of both worlds, cushioning, resisting movement while still absorbing outside shock and pressure.
At Cactus Container, a computer controlled ban saw is used to cut foam inserts. The steel blades are set to 15,000 lbs per square inch, allowing a precise cut foam insert. The customized cut foam insert is ideal for items such as a custom tool foam insert, computer hardware or electronics.
Convoluted foam has cone shaped peaks and valleys. The convoluted foam is similarly shaped like egg crates. When the convoluted foam inserts are placed together, the pieces interlock. The teeth-like texture of convoluted foam is more efficient than a flat foam insert. The impact is diffused at the base of the cone. The tip of each foam absorbs pressure, impact, and shock.
Similar to a convoluted foam insert are corrugated partitions. Corrugated partitions are shaped with up and down waves, which look like the ridges of a potato chip. The curves of a corrugated partition acts as a cushion. The corrugated partition resist impact . It’s curvy shape withstand outside pressure, securing and keeping the interior product intact.
A different box insert is a chipboard partition. It is typically smooth texture and at a much lower cost compared to corrugated partitions. While it still protects the product during packaging and shipping, a chipboard partition require less warehouse space than the corrugated partitions.