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The materials we in use in our foam products are listed on this page. Click Products to see pictures of some of the foam we have fabricated for our customers.
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We supply a variety of Specialty Flexible Foams including convoluted ELE.
Our years of packaging know-how enable us to provide our customers with protective
foam solutions from the materials listed on this page.
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The primary attribute of foam is its density. The foam density helps us describe
the foams ability to protect an object should it be dropped. The density ratio
affects things such as weight and the ratio of solid mass to air.
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1. Determine How Fragile the Object Is
Evaluate how fragile the object is by determining its g-factor. This is its fragility rating which can be determined by looking at the chart on this page.
2. Determine the Conditions the Object Will be Subjected to
Consider the "drop height" Consider the handling and transportation environment the product will face and establish the amount of shock the product may encounter ("drop height").
3. Determine the Cushion Requirements
Look up the information on the dynamic cushioning curves to determine thickness, static loading and bearing area required to cushion the object.
4. Analyze Design Constraints
Determine if potential problems exist for compressive creep, cushion buckling or extreme temperature issues.
5. Consider Vibration Effects
Determine if the object is prone to vibration damage, and compare it against the vibration characteristics of your package design.
6. Create Prototypes and Test
Construct a prototype and analyze its actual performance.
7. Perform Ongoing Performance Monitoring
Determine if your design continues to function as desired. Monitor for internal changes in the design that may alter the requirements for package performance.
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Typical Fragility for Packaged Objects
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Extremely Fragile |
Aircraft altimeters, gyroscopes, objects with precise technical alignments |
15-25 g's |
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Very Delicate |
Medical diagnostic equipment,
X-ray machines |
25-40 g's |
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Delicate
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Display monitors, printers,
test instruments, hard disk drives |
40-60 g's |
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Moderately Delicate |
Stereos and computers,
floppy disk drives |
60-85 g's |
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Moderately Rugged |
Major appliances, furniture |
85-115 g's |
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Rugged |
Power saws, washing
machines, machine tools |
115 g's and up |
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The best way to determine the fragility of an object is by subjecting it to a series of gradually more severe shocks (decelerations) in order to find the smallest impact that will damage it. The highest deceleration that causes no damage gives the object’s g-factor.
Some objects are more fragile in one direction than in another so it may be necessary to determine fragility levels for it in differing orientations.
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Urethane Foam
We can supply anti-static Urethane foam; colors include pink or blue.
Urethane foam includes Ether-like Ester ELE, Ether and Ester described
below.
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Ether-like Ester ELE Foam
This foam has a density of 1.6 lb.
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Ether Foam
Light weight foam that comes in 1.2 lb density. It is a less
expensive foam than the other urethanes.
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Ester Foam
The cell size is noticeably larger to the eye than with the other Urethane foams
and comes in 4 lb. and 6 lb weights. This is a high-density foam.
An example of Ester is the brown colored foam in our home page banner.
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Polyethylene Foam
This is a High-Density Closed-Cell foam for protecting heavier and/ bulkier items.
Polyethylene also comes in a version called High-Density Cross-Linked Closed-Cell.
This looks like rubber, but is softer.
We also work with Conductive Polyethylene and anti-static Polyethylene foam; available
colors are pink or blue.
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Expanded Polystyrene EPS
EPS is Expanded Polystyrene. This is what people commonly think of as styrofoam
used in the cardboard box packaging when you purchase a television, computer or
stereo system for example.
EPS Benefits
The Benefits of fabricated EPS Packaging is that it allows the customer
maximum protection without the tooling expense associated with custom molded parts.
Fabricated components are hot wire cut from computer generated patterns and if necessary,
assembled together to provide a packaging solution specific to the customer’s needs.
This method is well-suited for lower volume product lines where toolng costs cannot
be justified yet a custom part is still required. EPS is comprised of 90 percent
air. The shock absorbing properties and other qualities of EPS foam, combined with
its low-cost, high insulating properties and ease of processing make it a popular
packaging material.
EPS Advantages
Excellent protection and cushioning
Completely contains the product
Low abrasion
Reduces packaging inventories
Lightweight – reduces shipping costs
Ease of assembly increses production
Moisture does not weaken EPS
Thermal protection for the product
EPS contains no CFCs, HCFCs or HFCs
Chemically inert
EPS is recyclable material
Waste to Energy safe
EPS Appliactions
Box Liners
Trays
Endcaps
U-Channels
Displays
Melmat, Inc. is committed to providing the highest degree of care in maintaining
the health of our environment. We are proud of our recycling achievments as they
relate to reusing the materials we use during our manufacturing processes. Waste
to Energy Safe- EPS provides a clean source fo WTE inceneration systems. The simple
chemical make-up of EPS is carbon and hydrogen. These elments are the same as are
found in wood and other organic materials. EPS ash is therefore non-toxic – no unsafe
chemicals or heavy metals are produced when burned as fuel.
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