This is not the cheapest filler available on the market. However, it excels as packaging material in terms of packaging safety and the accuracy of filling void spaces. If you consider additionally the easy method and speed of packaging while using it, it turns out you have got an ideal filler. And it is simply an inconspicuous plastic bag with polyurethane foam injected inside. It is worth taking a closer look at this material.
Polyurethane foams are very common. They are widely used in construction as fitting and insulation material. They are ideal for the installation of window and door frames and filling the gouges in foamed polystyrene insulation. You may use them as an adhesive for drywall, and even to build a wall. However, not everyone knows that polyurethane foam is also a great filler for courier packages.
How does polyurethane foam work?
It may expand differently depending on the specific type of mixture used. Standard foams increase their volume by 70-120 percent while low-expanding ones by 30-60 percent. The foam used as a filler can increase in volume after application by up to 280 times the volume of the original liquid.
While expanding, the foam tightly fills all void spaces in its way. In a short time, due to moisture absorbed from the air, the polyurethane solidifies.
Solid polyurethane foam is a very light material offering excellent mechanical properties, that is simultaneous high elasticity and high shock resistance, as well as thermal insulation.
Foam in a bag
Polyurethane foam cannot be applied directly onto the object to be packed. Due to its strong adhesive properties you could damage the surface of the object or the object itself (e.g. electronics), although for sure it would be well protected against mechanical damage. However, the foam may be applied to an object covered with a protective layer, e.g. stretch film. Then you have nothing to worry about.
But the easiest way is to use foam in bag that will easily adjust its shape to that of the goods to be cushioned. You may make such a filler at home, it is not a problem. You will need only to gather strong plastic bags of the size you need and low-expanding polyurethane foam. Of course, you have to know how to apply the foam.
It will be much easier, although undoubtedly more expensive, if you use pre-made, hermetically sealed bags with a container filled with polyurethane foam. You have to crush the container which starts the foam expanding inside the bag and then – before the material solidifies – to make a sandwich. You place one bag on the bottom of the cardboard box, then goods on it, and cover them with another bag on top. After the polyurethane foam solidifies in the closed cardboard box you get a perfectly matched fitting.
You may buy foam-in-bag fillers in small or huge quantities. However, if you use a lot of them, you should consider your own production line of polyurethane foam fittings.
Easy production of ready-to-use fittings
If you sell large batches of the same goods, you do not have to use foam-in-bags every time you package your goods. You can order ready-to-use fittings or produce them yourself. Your own production requires you to purchase machines, which are designed to precisely inject foam into bags. Of course, your in-house produced fillers can be used for continuous packaging.
Your own production line is the optimal solution when usage of space is important, as machines and materials for production take up much less space than ready foam fillers or fittings.
From porcelain to a bulldozer
Foam-in-bag fillers are perfect for packaging small, fragile objects (glass or porcelain products). They excel as well when securing even large-scale production or construction machines.
The foam expands quickly and can be used to fill any space – from a small cardboard box to a container for sea transport. It can be successfully used as cushioning, but also as a perfectly fitted container.
Items secured with polyurethane foam do not move, they are well cushioned and protected against damage even in the event of high pressure. The foam packaging is like a light, durable and resistant cocoon. It wins the competition among all the fillers available on the market in terms of the easiest and quickest method of application.
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