The foam industry has come a long way. Now foam can easily be called one of the most versatile industrial materials of all time. Used for everything from insulation and flotation devices to furniture cushions, it can even be hardened into parts for furniture. Every day innovators come up with new uses for it.

The manufacturing of foam is a highly complex chemical process. However, it's not necessary to understand that process to be able to appreciate its many qualities, or to understand what kind of foam you need to buy. Density is the main criterion for choosing foam. The denser it is, the more resilient and resistant to pressure it is.

The identification force (IFD) is the load bearing force of foam. This is the force, measured in pounds, that is required to compress a foam sample that is generally 15 inches square and four inches thick. The number arrived at through this process will relate to the resilience of foam, and will indicate the uses for which it is suitable. Resilience, or how quickly the foam springs back into shape after compression, can also be measured through this test.

Foam Quality

Compression is not the only test to which foam is put in order to gauge its quality though. It is also stretched to capacity to measure elongation. This is the percentage of stretch that can be achieved before a length of foam breaks. Tensile strength is also measured by measuring the force that is needed to split or tear a length of foam after a nick has been made in the sample to start the tear.

Hysteresis is another test that foam samples can be subjected to in order to measure how much compression and stretching (use) it can be subjected to before it begins to permanently lose its springy character. The higher the hysteresis number the more highly desirable the foam is. These tests can be applied to all types of foam, no matter what their purpose. Indeed, such tests will be a good indicator of the purposes for which particular types of foam can be used.

Safer Foam Products

Since foam is, in its natural state, highly flammable due to the chemicals from which it's made, it has now become common practice to add a flame retardant during the manufacturing process. This makes the resulting foam product safer and more versatile. If you have questions about the quality of foam you're buying, then ask about the outcome of the above tests if they were carried out, and whether it has a flame retardant.

The latest in foam technology is spray on foam. This is catching on like wildfire in industries of all sorts, especially for packing. Foam in place packaging is the perfect answer for many companies who have to safely transport sensitive equipment or products over large distances, without incurring huge losses or high costs.

Most spray on foams are made from polyurethane or polyisocyanurate and are low density. Generally their density varies between 1.3 pounds per cubic foot to 2.0 pounds per cubic foot.

Uses for Foam Packing

Methods of using foam packing follow several different formats, but basically it's as simple as filling a carton or other container with the foam, and then placing the object to be packed into the foam, preferably inside a polythene bag. When the foam hardens the object is safely cradled and protected. This is especially useful for equipment where constant motion could cause damage. The foam, when it sets, provides more stability than any other form of soft packing.

Foam in place packing can even be used for high speed void filling, as for example in the back of delivery truck. Filling the spaces between cartons eliminates the possibility that they will shift and topple during transit, causing damage to the content. Spray on foam will adhere to any clean, dry surface that is free from debris.

A major advantage with in place foam packing is that it expands up to 200 times its original size on use, so it can save an enormous amount of space in storage. If you need to reuse your foam, you can create foam filled bags that can be used repeatedly for packing and cushioning purposes, although this will not give the exact fit that is required for the packing of some items. For complex engineering items, tailor made packing can be pre-manufactured using a mold, a polythene container and liquid foam. Using simple wood molds, it is possible to make a wide range of specially shaped cushioning containers for just about any item you want to pack.

Spray On Foam

Spray foam is actually created at the point of spraying, which is why it expands so much in size at this point. There are actually three different methods for making foam. Originally, foam was made by pouring the chemical components into a high speed rotary mixer and this method is still used for foam products. Then came frothing, which is a process very similar to pouring. Spraying is the true innovation. It saves a lot of time and effort and is extremely versatile, since if you have the necessary equipment you can use it anywhere. Occasionally a customer will be disappointed to find that spray on foam is not suitable for their purpose. Although it's rare, if this is the case with you, remember that many spray on foam applications also offer the option of having a pour on facility too.

Foam is cheap and easy to produce, weighs hardly anything, and can be replaced in a snap. These are just a few of the advantages. If foam has any drawbacks, it is chiefly that foam is made of chemicals so often foam gives off gases after it's produced. To avoid the issues of outgassing from foam, make sure the area is well ventilated for a few days after installation.