LAMINATED POLYETHYLENE FOAM

Polyethylene foam is relatively hard, as it is a low-density closed-cell foam that can be easily fabricated and flexible. This makes it ideal for packaging as it repels shock energy with a bounce, compared to the softer, open-cell foam of Polyurethane, which distributes shock on a broader scale. 

The closed cell structure of the polyethylene foam makes it incredibly moisture-resistant and non-absorbent. To ensure that it is fully waterproof, higher-density sheets must be used and then laminated.  

Polyethylene foam can last up to 10 years when made properly. Archbond’s lamination processes are sophisticated and create long-lasting PE foam, useful for a wide range of applications.  

The three types of foam lamination include: 

Flame lamination: This involves exposing a piece of material to an open flame. This then creates a layer of molten polymer on the surface. This type does not require any adhesive and works best when bonding layers of foam to non-woven fabrics. 

Infrared lamination: This process also creates a thin layer of molten polymer on the surface of the material and doesn’t require any adhesive. The infrared process creates durable laminated foam-based products and is ideal for applications in the automotive industry. 

Hot melt: This process is different as it needs an adhesive to work but benefits from the end material forming quickly as it solidifies as soon as the adhesive has cooled.  

Polyethylene (PE) is one of the most common types of plastic and is used to create various plastic products, such as water bottles, shopping bags, drainpipes, milk cartons, plastic wrap, and more.  

Since Polyethylene (PE) is classified as class 4, this means it is 100% recyclable. To handle PE foam effectively, recycling companies are now using modern recycling machines.

Polyethylene is a great candidate for food packaging. It can be used to make a soft-landing conveyor belt, which can be used for transporting fruit and vegetables. In its solid form, PE foam is non-toxic to humans, making it extremely safe for food packaging.  

The best thickness for PE foam will depend on the intended application. For example, packaging that requires thinner foam should range from 1.5 mm to 3 mm while thicker foams used for heavier and fragile items will be around 12.5 mm.