Cushioning Materials 1

CUSHIONING MATERIALS
12/25/2019 URL - http://www.iip-in.com 1

Goal of Packaging
 To get a product from one place to another

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

Global Transportation Options
 Major international transportation modes
‐ Sea
‐ Air
‐ Road
‐ Rail

Dynamic forces in distribution
 A package undergoes
‐ Manhandling
‐ Warehousing handling equipment
‐ Vehicle impacts
‐ Vehicle vibrations

Cushioning
 Cushioning is that part of packaging which protects

the article from damage due to shock and
vibration.
 During transportation a package may be

subjected to vibration over a wide range
frequencies and undergo joint of varying force
and duration.

Cushioning Cont…
 A cushioning materials selected for the purpose

may also have to minimize the movements of
the item, prevent abrasion of surfaces, barriers,
friction over sharp projection, absorb liquids
that are spilled from broken unit containers and
sometimes act as heat insulators.

Common types of cushioning
 Loose fill
 Paper
 Corrugated fibre board
 Foam structure

Advantages
 The entire range of cellular polymers from rigid

to flexible is used for packaging because of
their:
– Low cost,
– Ease of application,
– Fabrication,
– Moisture susceptibility,
– Thermal conductivity and
– Mechanical properties (especially compressive
properties)
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URL - http://www.iip-in.com
Applications
 Protective packaging:
As cushioning and packaging material for precision
instruments,
‐ electrical equipment,
‐ furniture,
‐ roofing and etc.
‐ PS products make economical packaging material that
insulate and absorb shock

Functions of cushioning
 Protecting the product from shocks and

vibrations.
 Protecting of delicate and highly finished

surfaces against abrasion.
 Protecting small projections on an article.
 Filling the void space in the container.

Classifications of cushioning materials
Cushioning Materials
Space Fillers Resilient Non-resilient

Classification of Cushioning Materials Cont…
 Space fillers are mainly used to fill the voids in

packages as dunnage prevent reorientation of the
items and sometimes to absorb liquid products
spilled from the broken unit containers.
 Resilient cushioning materials are used to protect

packaged items from damage due to repeated shocks.
 Non-resilient rigid cushioning materials are used for

protecting packaged items from a single severe shock
as is experienced in an air dropping.
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Classification of Cushioning Materials
 Granular form
 Bulk fiber
 Strips
 Matted fibres-textures
 Cellulose materials
 Foam plastics
 There are special cushioning devices, which are
metal springs, fibre straps and rubber shock
mounts

Space Fillers:
Granulated Materials
– Saw dust and coir pith
These are cellulosic materials and are cellular in structure and granular in
form. They have fair low bulk density and high compression strength.
They are highly absorbent.
– Granulated Materials
Ground Cork: Cork is made from the outer bark of the holm oak. It is
tough, light and elastic nature. Mainly used as space filling cushioning
materials. It has fairly low bulk density, high compression, fair residence and
good damping properties. However, it is also corrosive and poor fungus
resistance. It has high dusting characteristics and can contaminate the
unprotected items.
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Space Fillers:
Granulated Materials
– Kieselguhr
This is a fine white siliceous powder containing the remains of algae
used as a space filler, particularly abound tins of liquid chemicals as it is
non-inflammable and inert and will readily absorb most liquids
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Fibres and Strips in Bulk Form
– Paddy straw and dry grass
– Wood-wool
– Paper shavings

Fibres and Strips in Bulk Form
– Creped cellulose wadding
– Extruded or shredded foam plastics
– Corrugated fibre board

Resilient cushioning materials
 Bonded fiber mat

 Rubber-closed cell expanded rubber
 Rubber open cell
 Springs and shock-mounts
 Plastic foams

Air cushioning
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Properties of cushioning materials
 Resilience
 Compression
 Rate of recovery
 Damping
 Corrosion

Properties of cushioning materials Cont…
 Micro biological properties

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

Foam Structure
 Definition:
Foam is a substance where
air or gas bubbles are trapped
inside a solid or liquid.
 Types of foams:
Thermoplastic
Thermoset

Basic requirements for foam formation
 Accurate metering or weighing

 Temperature conditioning
 Freedom from contamination
 Effective mixing
 Curing environment
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Applications Cont…
 Flexible and semi flexible foams:

‐ Furniture ,
‐ Transportation,
‐ Bedding, textiles,
‐ Toys and novelties,
‐ Sports applications and etc.,
 Rigid foams:
‐ Building construction,
‐ Appliances,
‐ Transport,
‐ Furniture,
‐ Flotation,
‐ Molding,
‐ Food and drink containers (Packaging)
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Additives
 Colorants (titanimum dioxide, iron oxides)

 UV Stabilizers (benzotriazoles, benzophenones)
 Flame Retardants (cholorinated phosphate esters, melamine
powder)
 Plasticizers (phosphates, phthalates)
 Cell-Openers (paraffin oils, waxes)
 Compatibilizers : amines, fatty acids, hydrocarbons oils,
phthalates, polybutylene, glycols and ureas
 Auxiliary Blowing Agents : chlorofluorocarbons, methylene
chloride, methyl chloroform and
acetone
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Foam morphology
Polystyrene

Blowing Agent Selection
 Selection of suitable blowing agents for each polymer is very important for
producing dimensionally stable foams with desired cellular structures and
physical properties required in various end-use applications.
Ex: High solubility of blowing agents at high processing temperatures and

low solubility at the ambient temperature is desirable for improving
processability due to lower system pressure, better blowing agent mixing,
and better cell size control and also for improving physical properties due
to less plasticization of the cellular polymers.
 A suitable blowing agent should have low toxicity, low flammability, low
ozone depletion potential, low global warming potential and low cost.
Ex: pentane
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Manufacturing Methods
 Bubble initiation: the development of bubbles within a liquid

or polymer solution.
 Bubble growth: the initial bubble is ideally a sphere that grows as a

result of the interaction of the different pressure
between the inside and outside of the cell and
the interfacial surface tension.
 Bubble stabilization: if bubbles are sparsely distributed, as in high-

density foams, they will occurs as spherical cells
because that is the stable shape. If the foam is less
dense, cell wall stability is achieved by careful
control of the factors that influence membrane
thinning
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Foam Manufacturing
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Lab size foam
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Mixing Heads
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Commercial-size box foamer
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Conventional crowned-block process
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Extrusion Process
 Plasticating and pumping of the base polymer
 Dispersing and solubilizing blowing agent in the

polymer melt
 Cooling the resultant mixture to a uniform low

temperature
 Shaping the melt through a die orifice sized to maintain a

sufficient die pressure to prevent pre-foaming
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Extrusion Process Cont…
Primary Extruder: 1). two stage screw

2). Plastication and pumping in the first
stage
3). Mixing of the blowing agent in the
second stage
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Cushioning methods
 Blocking and bracing

 Floatation/ stuffing
 Wrapping
 Suspension
 Molded enclosures

Cushioning Methods
 Blocking and bracing

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

Plastic foams used in cushioning

Expanded polyethylene

Properties of PE foams
 It is resistant to common acid alkali and solvents

 Non-water absorbing
 Non-corrosive and non-dusting
 Stable to temperatures ranging between -20o C
to +70 o C
 It has fair resilience, good damping ,low creep and
fair value of compressions set.

Uses of PE foams

Advantages of PE
 Excellent cushioning to prevent

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

Expanded Polystyrene Foam
Properties of EPS
 Poor water absorbent
 Low dusting
 Stable to temperatures ranging from -30 o C
to 70 o C
 Resistant to acids and alkalis
 Fair resilience, good damping and low creep
 EPS has a good insulation capability and a good
first drop cushioning performance
 EPS foam is commonly found in protective cushion
pads like end caps

Cushioning methods Honey Comb
 Honeycomb is a material consisting of Kraft-liner

formed into continuous uniform hexagonal cells.
 Due to the wide range of applications, the
honeycomb can be considered as both inner and
outer packaging.
 Apart from blocking and filling, it can also be
used as a shock-absorbing product, a product
separator or even as a pallet.
 It can be used to protect anything from small
electronic components to large generators for
shipment.
 Packaging can be designed for products as light as a
cell phone or as heavy as several tons of automotive
parts.

Cushioning methods Honey Comb Cont…

Miscellaneous methods
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
– Antistatic poly urethane (PU) foam
– Specialized custom reticulated foam (PU)
– Foam-in-Place
– Kraft paper
– Custom Wood Assemblies

Cushioning material- Corrugated Board
Used as
– Pads
– Separators and inserts (double faced)
– Wrappers (single faced)
– Limitations
– Limited shock absorption capability
– Non resiliant
– Absorbs moisture

Cushioning material- Corrugated Board Cont…
Applications
– Filled glass packaging wrapping
– Handicraft products
– Wrap furniture's
– Wrap machine parts

Air cushioning (Bubble wrap) methods
 Increased cushioning properties

 Reduced material cost
 Labor savings
 Lower shipping costs

Properties of PU
 Non corrosive
 Low dusting
 Stable to temperatures between -10 o C to 55 o C
 Good resilience and damping with low creep and
low compression set.

Advantages of PU
 It can be easily molded into custom shapes

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

Foam in Place
 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.
 In a very short space of time, the foam expands
more than 200 times

Foam Profiles
 Foam profiles are easy to convert which gives

great possibilities in terms of customization.
 Corner protection - normally L-shaped

– Edge protection - normally U-shaped
– Tubular protection profiles

Foam
 The foam also has good resiliency and absorbency and is ideal for packaging light
products. Foam-in-place and foam-in-bag packing foam are used when a snug fit
around the product is desired.
 When used for packing and shipping, this foam protects objects from rain and
other sources of moisture.
 Polyethylene is a class of thermoplastics practically ubiquitous in consumer

products. In its foam form, polyethylene is used in packaging, vibration
dampening and insulation, as a barrier or buoyancy component, or as material for
cushioning.
 Expanded polystyrene sheets, packing peanuts, foam-in-place and foam-in-bag,

and polyethylene sheets are all types of packing foam.
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Foam
 Polyurethane can be flexible or rigid and can be made as sheets, as foam-in-
place, or as foam-in-bags. When made into sheets, this packingfoam can
either be made into a soft, flat sheet or into an egg-crate looking sheet.
 The material also permits more air circulation, and many hospitals use medical
grade convoluted foam as bedding material to reduce the risk of decubitus
ulcers, or bedsores. Convoluted foam is also a superior packing material. Due
to its cone-shaped pattern and ability to nest, products can be completely
encapsulated when wrapped for shipping to help resist movement during
transport.
 Foam ear plugs are small pieces of soft molded foam that are inserted into the
ear canal to block noises. Foam ear plugs may be used simply to block the
sounds of snoring, or they may be used at places where hearing damage is a
concern, such as a loud concert, noisy workplace, shooting range, or on a
motorcycle, just to name a few.
 The most recognized use for Styrofoam™ blocks is for packing and shipping,
but Styrofoam™ blocks can be applied to a myriad of projects.
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CUSHION DESIGN CONSIDERATIONS
 PRODUCT FRAGILITY
 CUSHION CHARACTERISTICS
 HANDLING HAZARDS
 STORAGE PERIOD
 TEMP. & RELATIVE HUMIDITY

Factors Effecting on Packaging Design
 When designing packaging, the choice of cushioning
may depend on many factors:
 Effective protection of product from shock and

vibration whether cushioning is resilient
(performs for multiple impacts) resistance to
creep, cushion deformation under static load,
material costs labor costs, productivity etc.
 Effects of temperature, humidity, and air pressure on

cushioning cleanliness of cushioning (dust, insects,
etc.)
 Effect on size of external shipping container

environmental and recycling issues sensitivity of
product to static electricity etc.
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Factors Effecting on Packaging Design Cont…
 Effects of temperature, humidity, and air

pressure on cushioning cleanliness of
cushioning (dust, insects, etc.)
 Effect on size of external shipping container

environmental and recycling issues sensitivity
of product to static electricity etc.
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Advantages
 Neat appearance
 Low space requirements until used
 Cost Effective
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Disadvantages
 Environmental disposal problems Labor

intensive(when used for cushioning)
 Packaging is labor dependent Performance
adversely affected with change of pressure
 Loss of air in one unit compromises entire
package / 30% failure rate(inconsistent
protection. Must be completely around
product in all directions to be effective(both
axis)
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THANK YOU

Cushioning Materials 1

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CUSHIONING MATERIALS

12/25/2019 URL - http://www.iip-in.com 1

 To get a product from one place to another

12/25/2019 URL - http://www.iip-in.com 2

 Major international transportation modes

12/25/2019 URL - http://www.iip-in.com 3

‐ Warehousing handling equipment

12/25/2019 URL - http://www.iip-in.com 4

 Cushioning is that part of packaging which protects

 During transportation a package may be

12/25/2019 URL - http://www.iip-in.com 5

 A cushioning materials selected for the purpose

12/25/2019 URL - http://www.iip-in.com 6

12/25/2019 URL - http://www.iip-in.com 7

 The entire range of cellular polymers from rigid

12/25/2019 URL - http://www.iip-in.com 9

 Protecting the product from shocks and

 Protecting of delicate and highly finished

 Protecting small projections on an article.

 Filling the void space in the container.

12/25/2019 URL - http://www.iip-in.com 10

Space Fillers Resilient Non-resilient

12/25/2019 URL - http://www.iip-in.com 11

 Space fillers are mainly used to fill the voids in

 Resilient cushioning materials are used to protect

 Non-resilient rigid cushioning materials are used for

12/25/2019 URL - http://www.iip-in.com 13

Fibres and Strips in Bulk Form

– Paddy straw and dry grass

12/25/2019 URL - http://www.iip-in.com 16

Fibres and Strips in Bulk Form

– Creped cellulose wadding

– Extruded or shredded foam plastics

– Corrugated fibre board

12/25/2019 URL - http://www.iip-in.com 17

 Bonded fiber mat

12/25/2019 URL - http://www.iip-in.com 18

12/25/2019 URL - http://www.iip-in.com 20

 Micro biological properties

12/25/2019 URL - http://www.iip-in.com 21

12/25/2019 URL - http://www.iip-in.com 22

 Accurate metering or weighing

 Flexible and semi flexible foams:

 Colorants (titanimum dioxide, iron oxides)

12/25/2019 URL - http://www.iip-in.com 26

Ex: High solubility of blowing agents at high processing temperatures and

 Bubble initiation: the development of bubbles within a liquid

 Bubble growth: the initial bubble is ideally a sphere that grows as a

 Bubble stabilization: if bubbles are sparsely distributed, as in high-

 Plasticating and pumping of the base polymer

 Dispersing and solubilizing blowing agent in the

 Cooling the resultant mixture to a uniform low

 Shaping the melt through a die orifice sized to maintain a

Primary Extruder: 1). two stage screw

 Blocking and bracing

12/25/2019 URL - http://www.iip-in.com 36

 Blocking and bracing

12/25/2019 URL - http://www.iip-in.com 37

12/25/2019 URL - http://www.iip-in.com 38

12/25/2019 URL - http://www.iip-in.com 39

 It is resistant to common acid alkali and solvents

12/25/2019 URL - http://www.iip-in.com 40

12/25/2019 URL - http://www.iip-in.com 41