Foam-Control Insulation for Packaging.

For more than 60 years, molded polystyrene has been the material of choice for strength, lightweight protection, price and versatility. Whether it’s a small or large production run, the control you get with Foam-Control makes the best choice.

A breeze for operations.

Control means that your Foam-Control packaging and OEM products can be designed to make your operations run smoothly, and will complement your packaging and manufacturing processes.

Foam-Control components are quick and easy to assemble; no special handling is required. And even though Foam-Control has a national presence, we’re also the best local vendor you’ve ever worked with, offering great customer service, proven systems and on-time delivery.

For packaging: Protection without compromise.

Foam-Control gives you the flexibility to create the perfect protection for your product, and reduce shipping costs:

  • Available in a range of densities/Types for strength and cushioning
  • Shape mold or fabricate into almost any shape
  • Easily combined with other materials
  • Superior insulation value for temperature-sensitive products
  • Promotes recyclable and reduced packaging

Packaging Applications

Fabricated Packaging

Foam-Control cushion protective packaging is custom fabricated by hot wire cutting with computer aided design (CAD), and if necessary, assembled together to provide a packaging solution specific to your needs. This method is well-suited for lower volume product lines where tooling costs cannot be justified, yet a custom part is still required. This method allows you maximum protection without the tooling expense associated with custom molded parts. Foam-Control is an amazingly strong and versatile material. Consisting of over 90% air, Foam-Control provides protection, cushioning and ecologically safe insulation properties.

Fabricated Molded Polystyrene

Foam Control Always Comes in Green

Foam-Control helps make your packaging parts environmentally friendly. It’s 100% recyclable. It can be ground into granules and reincorporated into new Foam-Control products. Or it can be thermally processed into a resin that’s used to manufacture other new products.

The Environmental Role of Packaging.

Cushion protective packaging has an important environmental role – to reduce damage and breakage to manufactured products. Broken, unusable products end up in landfills, which are rapidly filling up. Products damaged in shipment need to be remanufactured. Additional raw materials are used to replace them. More fossil fuels have to be burned, creating carbon dioxides and sulfur dioxides that pollute our environment.

Very little energy is used to produce cushion packaging, but it protects many valuable products that require high energy to manufacture. By giving optimum damage protection, Foam-Control reduces the need to remanufacture and reship. By reducing product damage, Foam-Control saves resources.

Foam-Control is committed to providing the highest quality products and services. We’re proud of our recycling achievements and are committed to work harder for the protection of our environment.

Packaging and the Environment

Life Cycle Analysis.

A life cycle analysis by InFo Kunststoff e.V. compared molded polystyrene to corrugated cardboard. The study quantified the energy use, global warming potential, air pollution, and water pollution associated with 1 cubic meter of molded polystyrene packaging or corrugated cardboard packaging.

Results of the study clearly demonstrate the environmental benefits of molded polystyrene packaging when compared to corrugated cardboard packaging.

Life Cycle Analysis

Some people have the misconception that Molded Pulp Packaging is a more environmentally friendly choice than molded polystyrene packaging. Before making a packaging selection based upon misconceptions, do your research and ask the following questions:

  • Does cushioning performance from drop tests, vibration tests, temperature control, etc. need to be considered?
  • What are the environmental impacts of having to remanufacture goods damaged during shipment?
  • Does recycled content of the packaging really equal sustainability?

Get the facts about molded polystyrene and molded pulp packaging from the AFPR logo and EPS and Mold Pulp PackagingAlliance for Foam Packaging Recyclers.


Molded polystyrene foam is one of the most heavily debated materials when it comes to recycling. It’s been recycled successfully by businesses and consumers throughout the U.S. for over 25 years.

As reflected in the graphic, more than 118 million pounds was recycled during a calendar year. This figure includes 63.0 million pounds of post-commercial and post-consumer packaging and 55.7 million pounds of post-industrial recovery. Post-consumer and post-commercial recycling are defined as any material that is recycled after its intended end-use – while postindustrial recovery includes facility scrap that is recycled but never served its intended purpose as a packaging material or other end-use application.


This chart shows a notable growth for post-consumer and post-commercial recycling. This is supported by a strong reliance on high volume sources and proves the success of industry recycling efforts in the United States. Advances in recycling technologies, collaborative collection programs and new end-use markets have continued to broaden recycling opportunities.

Read the entire Recycling Rate Report from EPS Industry Alliance.

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