Custom EPS Packaging: Tailored Solutions for Superior Protection

When products are damaged during shipping, it hurts more than just the bottom line—it impacts your reputation. That’s why more businesses are turning to custom EPS products for packaging that truly protects. Expanded polystyrene (EPS) foam isn’t just lightweight and cost-effective—it can be shaped, layered, and adjusted to cradle even the most delicate items securely.

At Benchmark Foam, we create EPS packaging that fits like a glove, reducing damage while keeping shipping costs low. Here’s how custom EPS solutions make a difference—and what options you should consider for your products.

Why EPS? The Science Behind the Protection

EPS foam works because it’s more than just a cushion—it’s an energy absorber. When something bumps or drops a package, the foam compresses to disperse the force, keeping what’s inside safe. Unlike generic packing peanuts or loose fill, custom-molded EPS holds items firmly in place, preventing shifts that can lead to scratches, dents, or breaks.

Key Benefits of EPS Packaging:

• Lightweight – Adds minimal shipping weight, keeping costs down.
• Moisture-Resistant – Won’t soak up water like cardboard or paper.
• Thermal Insulation – Keeps temperature-sensitive goods stable.
• Reusable & Recyclable – Can be repurposed or processed after use.

Customization: Making EPS Work for Your Product

One of the biggest advantages of EPS is how easily it can be adapted. Whether you’re shipping electronics, medical devices, or fragile industrial parts, the foam can be shaped to fit perfectly.

1. Shape Molding – A Perfect Fit Every Time

Instead of forcing your product into a generic box, EPS can be molded to:

• Contour around curves and edges – No wasted space or unnecessary movement.
• Hold multiple items in one block – Think of a tray that carries both a device and its accessories securely.
• Include cutouts for labels or branding – Functional and good-looking packaging.

2. Density Variations – Adjusting for Impact Resistance

Not all products need the same level of protection. EPS foam comes in different densities, allowing you to choose:

• Low-density (1.0–1.5 lb/ft³) – Ideal for lightweight, non-fragile items.
• Medium-density (1.5–2.0 lb/ft³) – Balances cushioning and cost for most consumer goods.
• High-density (2.0+ lb/ft³) – Used for heavy industrial parts or high-value electronics.

3. Multi-Piece Designs – Better Protection, Less Waste

Sometimes, a single block of foam isn’t enough. Custom EPS packaging can include:

• Two-piece clamshells – Snugly encasing products from all sides.
• Modular inserts – Stackable sections for different components.
• Interlocking layers – Preventing movement during transit.

Industries That Rely on EPS Packaging

Beyond Protection: How EPS Improves Brand Value

Great packaging does more than prevent damage—it makes an impression. With EPS, you can:

• Add logos or text – Embedded branding for a professional look.
• Design for unboxing – Creating a memorable customer experience.

Sustainability in EPS Packaging

Some assume foam isn’t eco-friendly, but EPS is 100% recyclable. Many facilities process it into new products, and its lightweight nature reduces fuel use in shipping. Benchmark Foam also focuses on right-sized packaging, minimizing material waste without sacrificing protection.

Getting Started with Custom EPS Solutions

At Benchmark Foam, we don’t just sell foam—we solve packaging problems. Whether you need a prototype or full production run, our team works with you to:

• Analyze shipping risks – Where does your product need the most protection?
• Test different designs – Ensuring the foam performs in real-world conditions.
• Optimize costs – Balancing protection with budget-friendly solutions.

Ready to upgrade your packaging? Contact Benchmark Foam at 800-658-3444 or bfiinfo@benchmarkfoam.com to discuss custom EPS solutions. Your products deserve protection that fits.