In an innovative endeavor, we transformed the production process of electronic product end caps. The initial method involved crafting EPS foam end caps using a chemically activated two-part foam system molded around a wooden form. Unfortunately, this technique proved sluggish, operating at merely four cycles per hour and incurring substantial costs.

Recognizing the inherent drawbacks of two-part expandable EPS foam

—chiefly's non-recyclable nature—we embarked on a solution-driven path. The foam supplier's inability to meet customer shipping demands accentuated the need for change. Consequently, we devised a strategic plan that addressed production inefficiencies and environmental concerns.

We created end caps using recyclable polyethylene (PE) foam that was easily cut with a high-speed press. This allowed us to meet production demands, save costs, and reduce environmental impact. Our clients benefited from a 30% reduction in unit costs for protective foam end caps, which provided significant financial relief.

Furthermore, these PE foam end caps exhibited heightened protective capabilities compared to their two-part EPS counterparts. Their enhanced ability to withstand drop damage presented an additional advantage, ensuring better product preservation.