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What is Plastazote Foam and Why is it Used in Packaging?

Plastazote foam, an industry-standard material, is widely used in various packaging applications due to its exceptional properties and versatility. This article will discuss what Plastazote foam is, how it is manufactured, and its numerous benefits in the packaging industry, particularly in flight cases.

coloured foam

Introduction to Plastazote Foam

Plastazote foam is a closed-cell, cross-linked polyethylene foam that provides excellent cushioning and protection for various products and equipment during transit. It is part of the AZOTE family of foams, manufactured by Zotefoams, and has become the go-to material for high-performance foam packaging.

Closed-Cell Structure

Unlike open-cell foams that have interconnected cells, Plastazote foam’s closed-cell structure means that each cell is separate and not connected to its neighbours. This feature prevents the absorption of gases and liquids, making it water-resistant and buoyant.

Nitrogen Cells

Plastazote foam is composed of nitrogen cells held within a polyethylene material. These cells give the foam its unique properties, such as being lightweight, odorless, and non-toxic. Furthermore, its polyethylene composition provides exceptional chemical resistance against most oils, solvents, acids, and alkalis.

Manufacturing Process of Plastazote Foam

The manufacturing process of Plastazote foam involves blowing nitrogen into the polyethylene material before it expands. This method results in a foam with a consistent cell size and structure that can be easily converted and fabricated into various packaging solutions.

Foam Conversion Processes

Plastazote foam can be shaped and cut using different methods, including CNC routing, die cutting, water jet cutting, and heat lamination. It can also be easily bonded to other materials such as fabrics, wood, plastics, and metals, making it ideal for creating custom inserts for flight cases and other packaging applications.

Thermoforming

The cross-linked nature of Plastazote foam allows for easy moulding at low temperatures. This process, known as thermoforming, can be achieved through compression or vacuum moulding. The low softening temperature of polyethylene makes it easy to form without excessive heat, allowing for the creation of detailed profiles and precise levels of protection.

Key Benefits of Plastazote Foam in Packaging

There are numerous advantages to using Plastazote foam in packaging, especially in flight cases. Some of the key benefits include:

Lightweight and Durable

The foam’s lightweight nature makes it easy to handle and transport, while its durability ensures long-lasting protection for the items inside the packaging.

Excellent Impact Absorption

Plastazote foam’s ability to recover from repeated impacts makes it highly energy absorbent and an excellent choice for protecting fragile or high-value items during transit.

Water-Repellent and Buoyant

The closed-cell structure of Plastazote foam makes it water-resistant and buoyant, providing additional protection against moisture and water damage.

Chemical Resistance

Plastazote foam’s polyethylene composition provides exceptional resistance against most oils, solvents, acids, and alkalis, making it suitable for various industries and applications.

Easy to Work With

The foam is easy to shape, cut, and bond to other materials, making it a versatile option for creating custom packaging solutions.

Non-Toxic and Low Odor

Plastazote foam is non-toxic and has an extremely low odor, making it safe for handling and suitable for use in medical and food packaging applications.

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Plastazote Foam in Flight Cases

Flight cases are a popular choice for transporting valuable equipment and products, requiring a high level of protection. Plastazote foam is an ideal material for creating custom inserts that provide the necessary cushioning and support for the items inside the flight case.

Protective Inserts

Plastazote foam can be engineered to provide specific cushioning performance against shock, impact, and general mishandling. When combined with a sturdy flight case, this ensures the highest level of protection for the contents during transit.

Custom Profiles

The foam can be easily moulded or machined to create detailed recesses and profiles that securely hold items in place during transit, preventing damage from movement and collisions.

Aesthetic Appeal

With a range of available colours and its low odor, Plastazote foam offers an enhanced aesthetic appeal for presentation and branding purposes, making it suitable for use in sales pitches and presentations.

Tool Control Inserts

Plastazote foam is also commonly used for tool control in industries such as aerospace, medical, and automotive. By laminating contrasting coloured foams and creating recesses for tools, it becomes easy to identify if a tool has been misplaced or not returned to its proper location.

This tool control system not only ensures safety in critical applications but also improves productivity by preventing the loss of valuable tools and equipment.

Cushion Packaging

Cushion packaging is another widespread use of Plastazote foam. By moulding or machining the foam to match the exact shape of the items being transported, it can hold them securely in place while absorbing any vibrations or impacts during transit. Additionally, softer grades of the foam can protect delicate surfaces from scratches and scuffs.

Custom Tool Case

Returnable Packaging

Plastazote foam is commonly used in returnable packaging systems, where it serves two main purposes. First, it can be designed to hold parts or components securely inside a tote, preventing movement and damage during transit. Second, it can protect specialized surfaces, such as polished or painted parts, from damage.

Electronics Packaging

Static-sensitive devices, such as microchips and circuit boards, can be damaged by electrostatic discharge (ESD) during storage and transit. Plastazote foam is available in grades that can conduct or dissipate these charges, effectively protecting electronic components and devices.

Military Packaging

Military packaging requires specific criteria, such as protection for sensitive equipment or approval for explosives and munitions. Plastazote foam meets these requirements, with flame-retardant grades available that are tested to relevant defence standards.

Medical Packaging

Plastazote foam is widely used in medical applications, such as transporting implants, surgical instruments, and mobile medical devices. Specific grades can withstand irradiation or heat sterilization, making them suitable for a variety of healthcare packaging needs.

Archive Packaging

The purity, stability, and inert nature of Plastazote foam make it an excellent choice for archival storage. With properties such as low odor, low VOC, and resistance to microbial growth, it is suitable for the long-term storage and conservation of artifacts, works of art, and historical items.

Conclusion

Plastazote foam offers numerous benefits and applications in the packaging industry, particularly for flight cases. Its lightweight, durable, and versatile nature makes it an ideal material for protecting valuable items during transit. Whether used for protective inserts, tool control, or cushion packaging, Plastazote foam is a solution that can have a significant impact on your business.