Every year, companies lose millions of dollars to one seemingly small issue: damage during shipping. It’s one of the most common causes of product returns, warranty claims, and customer dissatisfaction. Yet it’s also one of the most preventable.
If you’re dealing with rising damage claims, it’s time to take a hard look at the one thing standing between your product and the hazards of transit: your packaging.
The good news? You don’t need a complete packaging overhaul. In many cases, you simply need to adjust the materials inside the box.
Why Packaging-Related Damage Is So Common
No matter how sturdy your box or crate may be, the real protection comes from what’s inside. And yet, many companies still rely on:
- Generic foam blocks or sheet stock
- Loose-fill materials like peanuts or paper
- Molded pulp trays or vacuum-formed plastics
These solutions often look good on paper but perform poorly in real-world conditions, especially when the product is heavy, fragile, oddly shaped, or shipped through rough handling environments (couriers, freight carriers, etc.).
Common problems include:
- Items shifting inside the box
- Impact damage during drops
- Vibration wear during transit
- Insufficient cushioning against crushing forces
When packaging doesn’t match the product, damage is inevitable.
What’s the Best Material to Reduce Damage Claims?
Foam is one of the most versatile and protective packaging materials available. When chosen and fabricated correctly, foam can absorb shock, resist vibration, dampen compression, and cradle products precisely where support is needed.
Why is foam the best option?
Exceptional Energy Absorption
Foam acts like a spring. It compresses on impact, reducing the force that reaches your product. Whether your product falls off a shelf or gets dropped by a delivery driver, foam buffers that energy and protects what’s inside.
Lightweight Yet Strong
Foam provides a high strength-to-weight ratio, which means you can reduce damage without dramatically increasing shipping weight or costs.
Wide Range of Material Properties
From soft and flexible to rigid and supportive, foam can be tailored to match the size, shape, weight, and fragility of any product.
Water- and Chemical-Resistant Options
Closed-cell foams resist moisture, oil, and solvents, making them ideal for industrial or outdoor-use components that need to stay dry and clean during transit.
Reusable and Sustainable Options
Foams like EPP (expanded polypropylene) can be reused for returnable packaging systems, reducing waste and long-term costs.
Custom Converted Foam Is Even Better
Simply placing a generic foam sheet or block in your box may not deliver the protection your product needs. But there’s another solution: custom converted foam offers you a serious advantage because it’s:
Designed to Fit Your Product Perfectly
At Amcon, we use die cutting, waterjet cutting, CNC routing, and other advanced fabrication techniques to produce precisely shaped inserts, cavities, or braces that match the exact dimensions of your product. No shifting. No guessing. No wasted material.
Engineered for Performance
We help you select the right type of foam (and the right thickness and density) for your application. This ensures you’re getting maximum protection without over-engineering or over-spending.
Built for Your Shipping Conditions
Is your product shipped by air, ground, or freight? Handled manually or with forklifts? Shipped once or in a closed loop returnable system? These all influence the best foam type and packaging design. We work with you to create a solution that’s built for your real-world logistics.
Lower Total Cost of Ownership
While custom foam may have a slightly higher upfront cost than generic alternatives, it drastically reduces returns, replacements, warranty claims, and bad customer experiences. This saves you money in the long term.
How to Choose the Right Foam for Your Packaging
There’s no single “best” foam. The right choice depends on your product’s needs, weight, fragility, and shipping environment.
Polyurethane (PU) Foam
Best for: Lightweight, fragile items
Pros: Soft, flexible, great shock absorption
Use Cases: Electronics, medical devices, instruments
Polyethylene (PE) Foam
Best for: Medium to heavy items needing both support and cushioning
Pros: Closed-cell, rigid, resists water and chemicals
Use Cases: Automotive parts, appliances, tools, equipment
Expanded Polyethylene (EPE)
Best for: Versatility!, one way or returnable packaging, items requiring “class A” surface protection, medium to heavy duty
Pros: Class A surface, excellent strength to weight ratio, easy to fabricate complex shapes
Use Cases: Packaging, case inserts, medical packaging, crating/road cases
Cross-Linked Polyethylene (XLPE) Foam
Best for: High-end packaging with visual appeal and protection
Pros: Smooth surface, excellent durability, great shock resistance
Use Cases: Branded packaging, case inserts, military/medical transport
Expanded Polypropylene (EPP)
Best for: Reusable packaging systems or heavy industrial products
Pros: High impact resistance, excellent recovery, reusable
Use Cases: Returnable shipping containers, robotics, aerospace parts
Anti-Static Foams (ESD-Safe) (PE, PU, & Zote options)
Best for: Sensitive electronics or circuit boards
Pros: Protects against static discharge during transit
Use Cases: PCBs, semiconductors, sensors
Amcon Foam Can Help You Reduce Claims
At Amcon is more than just a foam supplier; we’re your foam packaging partner. When you work with us, we guide you through a proven process to create a custom solution that performs:
- We evaluate what you’re shipping, how it’s being handled, and where protection is most critical.
- We help you compare material options based on cushioning, compression, moisture resistance, and cost.
- We design inserts, braces, or assemblies that secure your product in place, absorb impact, and support weight where needed.
- We can provide sample parts to verify dimensions or run drop tests.
From low-volume custom kits to high-volume packaging programs, we deliver production-ready foam parts that match your specs and timeline.
Don’t Let Packaging Be the Weakest Link
Now is the time to make a change to your packaging. You don’t need to redesign your entire shipping process. You just need to upgrade the foam inside your box.
Let us help you ship smarter. Contact us today for a free consultation.