Looking for Bespoke Foam Packaging with a wide range of materials?

We are proud to offer our clients a wide range of materials to meet their packaging needs. This include PE, PU and EPS. If you are looking for a bespoke foam packaging solution, you’ve come to the right place.

Let’s find out a little about us… Synergy Packaging are a leading designer and manufacturer foam packaging solutions in the UK. Whether you need  protective packaging to meet a new product requirement or a re-design of an existing pack, we can help. Synergy offers the complete package.

Our service ranges from packaging consultancy to design, manufacture, storage and distribution. Our team are here to assess your needs and offer the perfect solution that meets your criteria. We provide the highest quality service with customer satisfaction being our top priority. Contact us today for a FREE design consultation.

Our Range of Foam Packaging Materials

polyethylene foam packaging services

Polyethylene (PE) foam

Whether you want standard foam pads for lining a box or a tailored foam solution to protect your products, there is a PE foam solution to meet your specific requirements. PE foam comes in a wide range of colours, densities and sizes and brand names include;

  • Stratocell®
  • Polylam®
  • Nopaplank®
  • Novastrat®
  • Foampack®.

Foam End Caps

Conventional Polyethylene foam end caps and protective packs are made by die cutting the component parts and then heat bonding them together a form a 3 dimensional protective cushion.

Hinged Design Packs

By using a foam with a high density “hinge” we can produce as a 3D foam cushion without the need for heat bonding. The benefits of the hinge are as follows:

  • Production time is kept to a minimum, reducing manufacturing cost
  • The pack lays flat for transportation, reducing transport cost
  • The pack stores flat until ready for use, reducing storage cost

Jigsaw Packs

The parts are designed in a way that when folded and offered to each other, the resistance of the fit will lock the components into place to offer performance and protection in key areas.

Expansion Packs

The foam is designed to allows the material to stretch and expand, which gives a greater coverage with no extra material, maintaining maximum protection. If you then combine this type of foam packaging design with the hinged foam pack concept you will have a truly cost effective performance pack.

polyurethane foam packaging

Polyurethane (PU)

Die Cut Fabricated Packs

Conventional Polyethylene foam end caps and protective packs are made by die cutting the component parts and then bonding them together using adhesives to form a 3 dimensional protective cushion.

Profiled Foam Packaging

Conventional Polyethylene foam end caps and protective packs are made by die cutting the component parts and then heat bonding them together a form a 3 dimensional protective cushion.

Expanded Polystyrene foam packaging design and manufacture

Expanded Polystyrene (EPS) Foam Packaging

Polystyrene foam is used for a range of applications including packaging, thermal insulation and decorative mouldings. The main forms of fabrication of this material are using either a hotwire to form intricate shapes from a foam block or to mould the pre-expanded foam beads into the desired shape. Our sales will be happy to work with you through a process of design and develop the right solution for you.

Specialist Foam and Rubber Packaging

Specialist Foam and Rubber Packaging Products

As well as the extensive range of conventional foam packaging products we offer at Synergy Packaging, Utilising the wide range of equipment we have across there are a number of d services we can offer in the fabrication and conversion of other more specialised foam, rubber and polymer based substrates.

Applications include; Transit Case Inserts, Tatami/Gym Mats, Custom foam profiles and Cross-linked foam (XLPE) products.

Looking for a quote a free pack design?

We offer a completely free foam packaging design service with our manufacture orders. Simply contact our team for more information. With sites across the UK, we our you local packaging experts nationally.

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