Custom Foam Inserts

Packaging Solutions / Case Studies

Situation

One of our clients, an aerospace and medical manufacturer, had a unique challenge: they needed to secure their product in place without any movement, but the product did not have inserts to secure it within the packaging. The product was also too delicate to use straps to prevent shifting during transport.

Solution

At PSAP we normally use foam as a barrier to prohibit the product from making contact with the interior walls of the crate. However, in this case we knew that the best protection would be the use of a full foam interior in which the product would be set. We custom cut the foam to exactly match the design of the product itself. We were able to place the product inside the foam, eliminating all movement and protecting it from any vibration.

Outcome

No additional materials were required to secure the product. The client simply placed the product directly inside of the foam interior capsule. Due to this project’s success, the client applied the same process with the rest of his products. The client reports that freight damage claims have ceased since converting their crating systems to the PSAP solution. Prior to the conversion freight loss claims averaged $150K per year. The client’s overall business and subsequent shipments have increased by 40% projecting even more savings from the PSAP solutions.