Cushioning Systems

Applications, Properties And Uses

1
 Goal of Packaging

z To get a product from one place to

another without unacceptable loss or
damage in an economic and practical
manner.

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 Packaging in Supply Chain

Figure 7.1
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 Global Transportation Options

z Major international transportation modes

– Sea
– Air
– Road
– Rail

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 Dynamic forces in distribution

A package undergoes
z Manhandling

z Warehousing handling equipment

z Vehicle impacts

z Vehicle vibrations
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 Functions of cushioning

z Protecting the product from shocks and

vibrations.

z Protecting of delicate and highly finished

surfaces against abrasion.

z Protecting small projections on an article.

z Filling the void space in the container.

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 Properties of cushioning materials

Resilience
Compression set
Rate of recovery
Creep
Damping
Corrosion
Hygroscopicity contd…...

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 Properties of cushioning materials

z Micro biological properties

z Dusting
z Abrasive characteristics
z Performance at low temperature
z Density

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 Cushioning methods

z Blocking and bracing

z Floatation/ stuffing
z Wrapping
z Suspension
z Molded enclosures

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 Definition : Shock Pulse

z Single Event
z High acceleration
(Deceleration)
z Very short time duration
(milliseconds)

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 Definition : Vibration Pulse

z Multiple Event
z Usually Low Acceleration
z Long time duration

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 Classifications of cushioning materials

cushioning materials

space fillers resilient non-resilient

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 Resilient cushioning materials

z Bonded fiber mat

z Rubber-closed cell expanded rubber
z rubber open cell
z Springs and shock-mounds
z Plastic foams

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 Resilient Foam

Plastic Foams used in cushioning

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 Resilient Foam

Plastic Foams

Plastic foams

Expanded Expanded
Poly urethane
Poly ethylene Poly styrene

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 Resilient Foam

Expanded poly ethylene

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 Polyethylene Blowing Agent

Blending

Extrusion + Blowing

Polyethylene Foam
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 Polyethylene

Cross-linking Blending Blowing Agent

Agent

Cross-linking

Blowing

Cross-linked
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Polyethylene Foam
 Resilient Foam

Properties of PE foams

z It is resistant to common acid alkali and

solvents
z non-hygroscopic and non-water absorbing
z non-corrosive and non-dusting
z stable to temperatures ranging between -20 o
Celsius to +70 o Celsius
z It has fair resilience, good damping ,low
creep and fair value of compressions set.

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 Comparison between extruded and
cross-linked PE Foams

z Chemical, Mechanical and thermal property of

extruded and cross-linked PE foams are very
similar.
z The cell size of cross-linked foams is generally
smaller and more uniform.
z Thickness dimension is more uniform in cross-
linked sheet as compare to extruded sheet.
z Cross-linked product posses a softer feel than
the extruded product.
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 Resilient Foam
Uses of PE foams

z Packing materials of
– various tiles,
– ceramic ware,
– glass ware,
– handicrafts,
– electronic goods
z Packing materials for instruments.
21 z Cushioning material for export of goods
 Uses of PE foams

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 Uses of PE foams

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 Uses of PE foams

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 Uses of PE foams

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 Uses of PE foams

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 Resilient Foam

Advantages of PE

z Excellent cushioning to prevent

scratching/bruising of item being packaged
z Lightweight - easy to handle
z Environmentally friendly
z Better protection against liquid spills, such
as chemicals and water.
z 100% waterproof

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 Resilient Foam

Expanded poly styrene

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 Resilient Foam

Properties of EPS

z non-hygroscopic,
z poor water absorbent
z low dusting
z stable to temperatures ranging from -30 o C
to 70 o C
z resistant to acids and alkalis
z Fair resilience, good damping and low creep.
z EPS has a good insulation capability and a
29 good first drop cushioning performance
 Resilient Foam

Uses of EPS

z EPS foam is commonly found in protective

cushion pads like end caps

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 Resilient Foam

Advantages of EPS

z Low cost
z Light weight
z Available in various colors
z Available in fire resistant variety
z Recyclable

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 Resilient Foam

Poly urethane

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 Resilient Foam

Properties of PU

z Non hygroscopic
z Non corrosive
z Low dusting
z Stable to temperatures between -10 o C to 55 o C
z Good resilience and damping with low creep and
low compression set.

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 Resilient Foam

Advantages of PU

z It can be easily molded into custom shapes

z suitable for a variety of products, from
extremely fragile to those with irregular
shapes and contours.

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 Resilient Foam

Applications of PU Foams

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 Resilient Foam

Foam in Place

z This packaging solution blocks the product

and gives protection against shocks. The
polyurethane foam is created through a
chemical process, where two liquids react
and expand rapidly.
z In a very short space of time, the foam
expands more than 200 times

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 Resilient Foam

Foam in Place

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 Resilient Foam

Foam Profiles

z Foam profiles are easy to convert which

gives great possibilities in terms of
customisation.
z Corner protection - normally L-shaped
- Edge protection - normally U-shaped
- Tubular protection profiles

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 Resilient Foam

Foam Profiles

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 Air cushioning

Buffer Filler
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 Modes of air cushioning

Air
cushioning

Encapsulated
Inflatable
Air
packaging
cushioning

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 Advantages of air cushioning

z ease of handling
z no hygroscopic
z highly versatile
z largely insensitive to extreme climatic
conditions (heat, cold)
z elevated recovery and ideal shock
absorption characteristics

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 Cushioning methods Air Pad

z Air pad is an efficient filling solution that can

also be used for blocking lightweight
products.
z This packaging solution fills the empty
spaces in the box, effectively protecting and
stabilising the product.
z Air pads are suitable for regular shaped
products without sharp edges and protruding
parts.
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 Cushioning methods Air Pad

z Benefits include:
- Reusable and recyclable
- Strong with extremely low weight
- Humidity insensitive
- Clean and easy to handle
- Very cheap solution for void filling

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 Cushioning methods Air Pad

z Since air pads can be formed at the point of

use, there is not a need for costly storage.
z The low weight reduces shipping costs and
make handling easier

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 Cushioning methods Air Pad

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 Air cushioning (Bubble wrap)

z Increased cushioning
properties
z reduced material cost
z labor savings
z lower shipping costs

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 Bubble Wrap cushioning

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 Cushioning methods Bubble wrap

Bubble wrap is a
z light and flexible packaging material made of
low-density polyethylene
z ideal to protect fragile and irregularly shaped
products.
z This gives a very good surface protection
and prevention against shocks.
z Bubble wrap can also be used as void filling.
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 Cushioning methods Bubble wrap

z Advantages and characteristics:

- Light and elastic
- Transparent, impermeable insulation
- Recyclable
- Improved product presentation
- Short packaging times
- Extremely good humidity resistance

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 Cushioning methods Bubble wrap

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 Cushioning material- Corrugated Board

Used as
z pads
z separators and inserts (double faced)
z wrappers (single faced)
Limitations
z limited shock absorption capability
z non resiliant
52 z absorbs moisture
 Cushioning material- Corrugated Board

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 Cushioning material- Corrugated Board

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 Cushioning material- Corrugated Board

Applications
z filled glass packaging wrapping
z handicraft products
z wrap furniture's
z wrap machine parts

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 Cushioning methods Honey Comb

z Honeycomb is a material consisting of Kraft-

liner formed into continuous uniform
hexagonal cells.
z Due to the wide range of applications, the
honeycomb can be considered as both inner
and outer packaging.
z Apart from blocking and filling, it can also be
used as a shock-absorbing product, a
product separator or even as a pallet.
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 Cushioning methods Honey Comb

z Low cost
z High strength - withstands top to bottom
compression
z Flexible design
z Completely recyclable
z Thermal conductivity and insulation abilities

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 Cushioning methods Honey Comb

z It can be used to protect anything from small

electronic components to large generators
for shipment.
z Packaging can be designed for products as
light as a cell phone or as heavy as several
tons of automotive parts.

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 Cushioning methods Honey Comb

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Miscellaneous methods adopted by packagers
to provide extra cushioning

z Loose fill cushioning materials

• 100% recycled expanded poly styrene loose
fill
• Starch based loose fills: ECOFOAM and
NATURPACK ®
• Corrugated loose fills
• Loose fill molded paper pulp (fiber flow®)
• Wood shavings (Curl pack ®)
• Popped corn
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 Miscellaneous methods adopted by
packagers to provide extra cushioning

z Antistatic poly urethane (PU) foam

z Specialized custom reticulated foam (PU)
z Foam-in-Place
z Kraft paper
z Custom Wood Assemblies

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 Cushioning methods

z Blocking and bracing

z Floatation/ stuffing
z Wrapping
z Suspension
z Molded enclosures

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 Cushioning methods

Blocking and bracing

z the main purpose of this solutions is to block
and fixate the product inside.

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 An Industrial application

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 Custom wood assembly

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 Packaging of Marble

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 CFB as Cushioning Material

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 Packaging in PS Foam Box

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 Loose Fill Application

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 Paddy Straw Application

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 Blocking Application

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 Blocking Application

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 Molded Paper Pulp

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 CUSHION DESIGN CONSIDERATIONS

1) PRODUCT FRAGILITY

2) CUSHION CHARACTERISTICS

3) HANDLING HAZARDS

4) STORAGE PERIOD

5) TEMP. & RELATIVE HUMIDITY

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 STEPS TO CUSHION SELECTION

1) ASSES DISTRIBUTION HAZARD

2) DECIDE ON NUMBER OF DROPS &

DROP HEIGHT

3) ASSES PRODUCT FRAGILITY

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 STEPS TO CUSHION SELECTION

4) CHOOSE CUSHIONING MATERIALS

5) MAKE PROTOTYPES

6) TEST PROTOTYPES

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