Foam

What is PE Foam?

PE foam is a flexible foam material made from expanded polyethylene, more precisely low-density polyethylene (LDPE). During production, the polyethylene granulate is melted in elongated tanks known as extruders, mixed with a blowing agent (CFC-free), and pressed through a die under high pressure. This process is called extrusion.

After extrusion, the foam is wound tightly and with straight edges onto a cardboard core and stored for a certain period to allow residual gases to evaporate. This ensures optimal material properties and dimensional stability.

Our foam sheets are extruded as standard in white (also referred to as natural) and are available in various thicknesses, widths, and roll lengths. The longer the roll length, the larger the roll diameter, which has a significant impact on freight costs.

For high-volume requirements, we recommend our jumbo rolls, as fewer rolls are needed and transport costs for partial truckloads can be reduced. For smaller requirements, short rolls or small rolls are the better option, as they can be shipped via parcel services, which are considerably more cost-effective than freight forwarding. Jumbo rolls exceed standard parcel size limits and therefore cannot be shipped by parcel services.

The surface feel (haptics) of PE foam can vary significantly depending on the manufacturer and intended use. Some foams have a wavy structure, while others are smooth. We primarily offer PE foam with a smooth surface. The internal structure of the foam also varies depending on the application and will be discussed in more detail in the respective sections below.

PE Foam as Transport and Product Packaging

One of the most important applications of PE foam is the packaging of shock-sensitive goods. The material provides excellent impact protection and is therefore ideal for cushioning and shock absorption. PE foam also offers high resistance to moisture, as it is water-repellent and moisture-resistant, making it effectively moisture-proof.

Although polyethylene foam is flammable, it has relatively high temperature resistance compared to many other packaging materials.

We supply LDPE foam packaging and transport protection in a wide range of designs and configurations. These include foam laminated with bubble wrap, foam with a fully self-adhesive backing, or foam laminated with nonwoven fabric (fleece) for particularly scratch-sensitive products. Upon request, virtually any type of coating or lamination can be supplied.

Special attention should be given to versions with LDPE or HDPE film lamination, as these significantly increase the tear resistance of the foam sheets.

Continuous Foam Rolls

PE foam supplied on rolls is ideal for custom packaging of large or irregularly shaped products. The material can be unrolled as needed and cut to the desired length. Predefined widths ensure easy handling and efficient processing.

For furniture packaging, we recommend wider rolls with widths of 1.0 m or 1.2 m. For smaller items such as computers, monitors, or televisions, narrower widths between 0.5 m and 1.0 m are sufficient.

In addition, we also offer ESD-protected PE foam. For standard electronic devices, our antistatic foam with a surface resistance of less than 10¹² ohms is suitable. For highly sensitive electronic components, we recommend conductive foam. Foam bags, flat bags, pouches, and sacks made from PE foam can also be equipped with antistatic additives to ensure that devices such as laptops or smartphones arrive safely without damage to sensitive electronics.

Flat PE Foam Bags

For protecting sensitive small parts against impact, dirt, and moisture, or for bundling products into sets, our PE foam flat bags are an excellent solution. They are available in many dimensions and in thicknesses ranging from 1 mm to 4 mm, allowing you to achieve optimal protection at a competitive price.

For enhanced visual appeal at the point of sale, our LDPE foam bags can also be produced in various colors, subject to minimum order quantities. Available colors include pink, rose, anthracite, black, green, red, and orange.

For particularly delicate surfaces such as displays, painted components, optical lenses, or eyeglasses we recommend PE foam bags laminated with an internal PP nonwoven layer. This effectively prevents microscopic scratches that are barely visible to the naked eye but can significantly affect product quality.

Our packaging specialist Janis Katsoulis will be happy to provide personalized advice to help you select the most suitable PE foam bags for your specific application: +49 7121 9118-59

Foam Cut-to-Size Parts, Polyethylene Foam Sheets and Die-Cut Parts

If cutting foam from rolls is too time-consuming for your application, we are happy to supply precision-cut PE foam sheets made exactly to your specifications. The production of die-cut foam parts is also possible.

Whether used as inserts for glasses cases, construction kits, intermediate layers, or protective inlays, we can die-cut virtually any shape and design. Of course, all foam cut-to-size parts and die-cut components can also be produced in an antistatic version. Self-adhesive foam cut-outs are also available upon request.

Self-adhesive PE foam is ideal for applications such as the interior lining of wooden crates or transport packaging. In this case, the foam acts as a permanently fixed shock absorber that remains securely in place.

For particularly heavy products or when a stable interlayer for pallet stacking is required, we recommend PE foam sheets. These sheets offer high resistance to compressive loads and provide excellent impact protection and shock absorption.

Their high strength and stability result from the manufacturing process. Thanks to their fine-cell, highly compacted structure, these foams are classified as cross-linked polyethylene foam. Cross-linked foam is characterized by exceptional rigidity and dimensional stability. Due to its compact structure, foam sheets of this type should be milled rather than cut when downsizing is required.

If such high-density foam sheets are more than you need and you simply want to prevent light goods from slipping on pallets, thinner foam mats with a thickness of 1–3 mm and a density of 16–18 kg/m³ are an excellent alternative as an underlay material.

Our packaging specialists will be happy to advise you on the most suitable foam cut-to-size solutions for your application.

Edge Protection Corners, Edge Protectors and Foam Profiles

We also supply a wide range of PE foam profiles with a minimum density (RG) of 33 kg/m³. Using U-profiles, L-profiles, O-profiles (foam tubes), or RS-profiles, available in blue and grey, products of almost any size can be reliably protected.

Thanks to the elasticity of the foam profiles, a certain tension is created during application, which prevents the edge protectors from slipping.

Our high-density PE foam pads, with densities of up to 60 kg/m³, are particularly strong and rigid, making them ideal as spacers or distance elements. These pads can also be supplied in self-adhesive or self-gripping versions. In addition to the profiles mentioned above, many other variants are available. Please contact our sales team for further details.

Polyethylene Foam Tubing

PE foam tubing supplied on rolls is especially suitable for packaging long products. For example, metal rods of various lengths can simply be inserted into the foam tube and cut to size, providing fast and effective surface protection.

PE Foam Netting / Fruit Packaging

We also offer PE foam netting in tubular form, which is food-safe. This type of foam netting is commonly used for fruit and vegetable packaging, with the Nashi pear being a well-known example from supermarket displays. It is also suitable for packaging other products such as glass bottles.

The mesh structure of the foam netting is elastic and highly stretchable, allowing the flat width to expand up to double its original size. This ensures an optimal fit and close adaptation to the packaged product. Our specialists will be happy to advise you on the right solution.

PE Foam as Void Fill Material

For cushioning and void filling, we supply PE foam chips or foam flakes. These are ideal for filling cartons and ensuring that products are securely fixed inside the packaging, effectively eliminating empty spaces.

Impact Sound Insulation and Thermal Insulation

Due to its excellent damping properties, our PE foam is ideally suited as an impact sound insulation layer under laminate or parquet flooring. Whether supplied on rolls or pre-cut to size, we manufacture according to your requirements.

Self-adhesive PE foam is particularly practical, as it prevents slipping during installation. The self-adhesive foam can also be used as edge insulation strips when laying laminate flooring. These edge strips are available in blue.

Insulation and Sealing

In addition to flooring applications, LDPE foam can be used in the construction sector for pipe insulation and thermal insulation. PE foams offer excellent insulating properties due to their low thermal conductivity, while remaining easy to process and handle.

The material can be cut with a standard utility knife and bonded easily using hot-melt adhesive. Alternatively, the foam sheets can also be welded.

Contact and Ordering

Has the versatility of polyethylene foam sparked your interest? If so, simply contact us by phone or email for personalized technical advice. You can also use our online enquiry form, and we will provide you with a non-binding quotation promptly.

If you have any questions, please feel free to use our contact form. If you already wish to place an order, simply select the appropriate product in our online shop and complete your purchase conveniently via PayPal or Amazon Pay. We offer free delivery within Germany. Alternatively, you may collect the goods directly from our premises. As PE foam is a voluminous product, a sufficiently large vehicle is required. Our sales team will be happy to advise you on the exact volume in advance.

We also ship to Austria, Switzerland, the rest of the EU, and worldwide. For our customers, no distance is too far!