PFI supplies custom polyethylene foam packaging and PE foam inserts that protect products from shock, vibration, and moisture in shipping, storage, and in-plant handling. We stock PE foam in a full range of densities and fabricate it into cut inserts, blocks, braces, and reusable trays built around your product. Buy stock sheets and planks to cut in house, or let us deliver finished custom packaging that is ready for your pack-out line.
Lower Than National Pricing
Delivery Across SoCal
Nationwide Shipping
CAD Design & Prototypes
Polyethylene foam is the workhorse of protective packaging. Its closed cell structure resists moisture and most chemicals, it bounces back after repeated impacts, and it holds up to reuse. PFI gives you every way to put it to work:
We help you pick the right density and thickness for your product weight and fragility, then cut to tight tolerances so each part fits securely without trimming or guesswork.
Each product needs a different balance of cushioning, stiffness, and cost. We stock and fabricate the following, and recommend the best fit for your application.
Soft, lightweight PE foam in the 1.2 to 1.7 lb range that cushions light and fragile items. It works well for surface protection, wrap pads, and inserts for small parts where low cost and low weight matter most.
PE foam around 2.2 lb gives you the most versatile balance of cushioning and support. It handles most general packaging, cavity inserts, and cushioning pads for medium weight products.
Firm PE foam in the 4 to 9 lb range supports heavy, dense items without bottoming out. It works best for load bearing blocks, skid runners, heavy equipment supports, and tool control inserts.
We die-cut, route, and laminate PE foam into custom inserts with a pocket for every part. Inserts keep items separated, speed up packing, and reduce damage claims.
PE foam blocks, braces, corners, and end caps hold heavy or oddly shaped products in place inside crates, boxes, and trailers. They absorb shock and stop load shift during transit.
Durable PE foam trays and case inserts stand up to repeated trips, making them ideal for returnable totes, tool kits, instrument cases, and supplier loops.
Density drives how firm the foam feels and how much weight it supports. Heavier products generally call for higher density foam, while fragile, lightweight items need a softer foam that can absorb shock. Use this guide as a starting point, and we will fine tune the choice to your product.
Density | Feel | Common uses |
1.2 lb/ft³ | Soft, very light | Surface protection, wrap pads, lightweight inserts |
1.7 lb/ft³ | Soft to medium | Small part inserts, void fill pads, light cushioning |
2.2 lb/ft³ | Medium, most versatile | General cushioning, cavity inserts, end caps |
4.0 lb/ft³ | Firm | Heavier products, tool control inserts, reusable trays |
6.0 lb/ft³ | Very firm | Load bearing blocks, heavy component supports |
9.0 lb/ft³ | Rigid | Skid runners, heavy machinery blocking, structural supports |
Both options use the same quality PE foam. The right choice depends on your volume, your team, and how much time you want to spend on the pack-out line.
You have in house cutting equipment or staff, your products change often, you ship low volumes or one off items, or you need foam on hand for repairs and returns. Stock foam gives you flexibility and the lowest material cost.
You ship the same products repeatedly, labor time on the line matters, damage rates need to come down, or your packaging has to look consistent for customers. Custom inserts cut packing time, reduce waste, and protect every unit the same way.
Not sure which fits? Many customers start with stock foam, then move their highest volume items to custom inserts once the design is proven. We help you make that switch when it saves you money.
Send dimensions, weight, a drawing, or a sample, and tell us how the product ships and how often. We recommend the density, thickness, and format.
We design your insert or blocking in CAD and build a prototype you test with your real product before any production run.
We cut, route, and laminate your PE foam to tight, repeatable tolerances, so every part drops into place on your line.
We inspect every order, then deliver next day across Southern California and ship free nationwide through our distribution network.
Buy sheets and planks or finished inserts from the same team, and switch as your needs change.
We match density and thickness to your product so you avoid overpacking or underprotecting.
We design and prototype your insert at no cost, so you confirm the fit before you commit.
Save 15% to 40% compared to national suppliers, with next day SoCal delivery and free nationwide shipping.
We provide local next day polyethylene foam delivery across Southern California:
Multi-location and out of state businesses ship from our nationwide distribution centers in CA, TX, IL, PA, TN, and GA, so every facility receives the same PE foam packaging.
Polyethylene foam packaging uses closed cell PE foam to cushion, block, and brace products during shipping and storage. It resists moisture and most chemicals, recovers after repeated impacts, and works for both one time and reusable packaging.
Lighter, fragile products usually need softer foam in the 1.2 to 2.2 lb range, while heavy or dense products need firmer foam in the 4 to 9 lb range. We review your product weight, size, and shipping method and recommend the right density.
Stock sheets and planks make sense for low volumes, changing products, or in house cutting. Custom inserts pay off for repeat shipments, faster packing, and lower damage rates. We help you compare both on cost and labor.
Yes. Send a drawing, dimensions, or a sample. We design the insert in CAD and build a free prototype for you to test before production.
Yes. PE foam holds its shape and cushioning through repeated use, which makes it a strong choice for returnable trays, case inserts, and supplier loops.
Polyethylene foam is closed cell, firmer, and resists moisture, making it ideal for blocking, bracing, and rugged inserts. Polyurethane foam is open cell and softer, so it conforms around delicate items. We supply both and recommend the right one for your product.
Yes. We supply anti-static and conductive PE foam for electronics and static sensitive parts. See our ESD foam packaging page for details.
