For years, foam and polystyrene have been the go-to materials for protective packaging. They’re lightweight and familiar, but they come with growing drawbacks. They’re made from
petrochemicals, difficult to recycle, and increasingly out of step with modern sustainability goals.
More businesses are now turning to bespoke corrugated solutions, like those developed by Samuel Grant Packaging, as a practical and cost-effective alternative.
Polystyrene might seem cheap on paper, but it often creates hidden costs. It’s bulky to store and transport, awkward to dispose of, and rarely recycled. In addition, environmental pressures, supply chain issues and customer expectations are pushing companies to rethink their packaging choices.
Corrugated packaging offers a clear way forward. It’s 100% recycled and recyclable and can be engineered to perform just as well as foam in protecting products.
Samuel Grant Packaging specialises in designing custom corrugated systems that are built around the product itself. Rather than relying on moulded foam inserts, these solutions use carefully engineered board structures to hold, protect and stabilise goods in transit.
As they’re bespoke, they can be tailored to fit products precisely therefore reducing movement and overall risk, whilst using less material overall.
Real Results: HVAC Manufacturer Case
One UK air conditioning company recently made the switch from foam to a Samuel Grant Packaging corrugated solution.
The outcome was immediate:
- Over 50% cost saving compared to foam
- Reduced packaging volume, allowing more units per shipment
- Easier recycling for customers
- Elimination of plastic-based waste
The savings don’t stop at material costs.
Corrugated systems can be supplied flat-packed, taking up far less space in storage and transit. That means fewer pallets, more efficient shipping, and lower transport costs overall.
They’re also easier to handle and dispose of, cutting down on labour and waste management issues.
Better for the Environment
Switching away from foam removes a significant amount of plastic from the supply chain.
Corrugated packaging is:
- Recyclable through standard waste streams
- Made from renewable sources
- Far easier to recover and reuse
Not a Compromise
There’s often a perception that moving away from foam means sacrificing protection. In reality, modern corrugated designs are more than capable of delivering the strength and durability required, even for heavier or more complex products.
Replacing foam with corrugated isn’t just a sustainability exercise. It’s a smarter way to package products, reduce costs, and streamline logistics.
