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This section provides an overview for plastic foam as well as their applications and principles. Also, please take a look at the list of 38 plastic foam manufacturers and their company rankings. Here are the top-ranked plastic foam companies as of December, 2024: 1.Alta Max LLC, 2.Monmouth Rubber & Plastics Corp, 3.Drew Foam Co, Inc..
Table of Contents
Plastic foam refers to molded synthetic resins containing air bubbles, resulting in porous materials with numerous independent and continuous pores, akin to the structure of charcoal and pumice stone.
The primary synthetic resin materials used for plastic foam production include polyurethane, polystyrene, and polyolefin, collectively known as the "three major foamed plastics." Foamed plastics derived from polystyrene are commonly referred to as styrene foam.
Industrial methods for forming air bubbles in plastic foam include direct gas mixing into the synthetic resin material and the use of foaming agents such as sodium bicarbonate, which are mixed into the resin material beforehand and activated by heat to induce foaming and bubble formation.
Plastic foam finds versatile applications due to its excellent cushioning, heat insulation, and buoyancy properties, making it suitable for various products and components across different industries.
Plastic foam serves as transportation and packaging material for agricultural and marine products, offering exceptional shock absorption, heat insulation, and lightweight characteristics. Polystyrene foam sheets (PSP) and polystyrene bead foam (EPS) are commonly used in packaging containers for fresh produce and seafood due to their thermal insulation properties.
Plastic foam is utilized in automotive components to enhance safety by providing shock absorption and reducing overall vehicle weight. Urethane foam and polypropylene resin (PP) are commonly used in automotive seat cushions, mattresses, and bumpers due to their softness, resilience, impact resistance, and cost-effectiveness.
Plastic foam serves as a building material for its excellent thermal insulation properties. Types such as beaded polystyrene foam, extruded polystyrene foam, rigid polyurethane foam, and phenolic foam are used in construction for their heat insulation effectiveness. These foams are also known for their moldability and flame retardancy.
The properties of plastic foam vary based on the synthetic resin type and bubble structure. Select foam type based on application requirements, considering factors such as heat resistance and bubble structure (independent or continuous).
Pre-molded plastic foam products can be directly utilized, while foam sheets can be shaped using molding machines. Ongoing research explores composite materials involving plastic foam and other substances to enhance strength.
1. Melt and Foam Molding Method
This technique involves mixing a blowing agent with molten resin to induce foaming. It is commonly used for thermoplastic resins like polystyrene and polyolefins.
2. Solid-Phase Foam Molding Method
Solid-phase foam molding produces foam from solid resin particles, used in products like EPS and EPP for fish boxes and automotive parts.
3. Injection Molding
Injection molding involves injecting liquid resin into a mold and foaming during curing, employed for polyurethane and phenolic foam production.
*Including some distributors, etc.
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Premier Protective Packaging, established in 2000 and headquartered in Grand Rapids, Michigan, is a manufacturer and national supplier of protective packaging materials. The company specializes in custom packaging applications using Polyethylene (PE) foam, bubble, and Non-Woven Spun Bond Polypropylene (SBPP) protective packaging materials. Its manufacturing technology incorporates state-of-the-art equipment for sheeting, bag pouch production, die-cutting, and laminating, enabling the creation of tailor-made packaging solutions. These are utilized to provide protection for various items during transportation and storage.
Drew Foam Companies, headquartered in East Monticello, Arkansas, has been operating as an EPS (Expanded Polystyrene) manufacturer since 1965. It functions as a full-service EPS block molding company with three facilities and a portfolio comprising over 16,000 specialty items. It specializes in offering expanded polystyrene foams, EPS foam packaging, Extruded Polystyrene Insulation, geofoam, and more. The company ensures product quality and timely delivery by utilizing its own fleet of trucks and drivers. It also incorporates up to 60 percent recycled EPS in its products, along with repurposing up to 300,000 pounds of waste materials on a monthly basis.
Atlas Foam Products, founded in 1992 and located in Sylmar, California, is a supplier and manufacturer of custom foam. The company offers a broad range of products, including polyurethane, polyethylene, expanded polystyrene, and neoprene. These foam materials are utilized across a spectrum of industries and applications, including packaging, insulation, automotive, aerospace,and construction. The company’s products are customized foam solutions used for product protection, insulation, comfort, and safety in diverse sectors and applications.
Plastic Technology Inc. is an American foam and foam molded products manufacturer that was established in Midland, Michigan in 1984. The company offers various foam materials including polyethylene, expanded polystyrene (EPS), and polyurethane foams, as well as various foam products such as headrests, seat cushions, and sound insulation panels. It also offers structural foam molding (SFM), reaction injection molding (RIM) and high pressure foam molding (HPFM) contract manufacturing services for unique customer projects. The company chiefly serves clients in America’s automotive, aerospace, and military industries.
UFP Technologies, established in 1963, based in Newburyport, Massachusetts, is a medical manufacturer and supplier of custom devices, sub-assemblies, components and packaging utilizing highly specialized foams, films, and plastics. The company's products include FlexShield, BioShell, CryoShell, T-Tubes, and Tri-Covers. Its products are used in medical devices, disposable wound care, infection prevention, minimally invasive surgery, and orthopedic implant packaging. Additionally, engineer products are provided to customers in the aerospace, defense, automotive, electronics, and industrial markets. In 2013, it was named to The Boston Globe’s “The Globe 100” for the 8th consecutive year.
Monmouth Rubber & Plastics Corp., founded in 1964, is an American manufacturer and supplier based in Long Branch, New Jersey, specializing in rubber and plastic foam. The company offers closed-cell sponge rubber and plastic foam under the Durafoam brand, while open-cell sponge rubber and plastic foam are offered under the Airaflex CF Series. The Duraflex brand offers plain and adhesive-backed solid rubber and plastic sheets, while the Bondaflex brand presents recycled rubber and plastic material composites. Additionally, the company offers various types of rubber buns, rolls, sheets, and foam tapes. These products find applications in various industries, including sports equipment and transportation.
Foam Products Corporation., founded in Calhoun, Georgia, in 1978 is a manufacturer of acoustical underpayments for LVT, vinyl plank, laminate and wood floors. The company's product portfolio includes double stick commercial carpet cushions for hospitality and commercial applications, wood wall planks and kitchen backsplashes, breathable waterproof protective films and coated fabrics and cushioning products. The company serves markets including Medical and Healthcare, Aerospace and Defense, Consumer Goods, Industrial Manufacturing and Construction and Building.
General Plastics Manufacturing Company, established in 1941 in the United States, is a manufacturer of polyurethane foam and built-to-print composite parts. General Plastics manufactures custom-mold parts using flexible and semi-flexible polyurethane foam materials. The company also can support sub-assembly, part and tool design, and custom foam services. General Plastics provides build-to-print standard and custom laminates for myriad parts and assemblies, and on-site testing laboratories, including an FAA-certified burnt test facility. Their products have various military, industrial, and commercial applications.
Polyfoam LLC, established in 1957 and based in Northbridge, MA, USA, is a manufacturer and supplier of molded plastics and foam molded plastics. The company's product range includes Expanded Polypropylene (EPP), Expanded Polyethylene (EPE), injected molded plastics, medication & vaccine shippers, and fresh & frozen grocery delivery containers. These products are used for grocery delivery, laboratory test kits, e-commerce food delivery, and serving meals in hospitals. They serve industries such as thermal packaging, food service, construction, and consumer products. The company's services include engineering design prototyping, ISTA testing, kitting finishing, and components production.
Universal Polymers Corporation has been manufacturing spray foams since 1983 in North America. The company manufactures light-density, Open-cell spray foam which is generally applied to interior walls that are above ground, onto the ceilings, and on the underside of the roof. There is also high-density, Closed-cell spray foam for interior and exterior applications as well as Roofing spray foam for roofs, tanks, and hot and cold storage facilities. UPC's parent company General Coatings Manufacturing Corp. also deals in various urethane, foam, and coating products other than spray foams.
Universal Foam Products is a Maryland, United States-based supplier specializing in Expanded Polystyrene (EPS) that can be customized into various shapes according to the customer's specifications. The company offers an extensive range of EPS products, including coolers, bottle shippers, packaging solutions, and products designed for marine and flotation applications. These EPS products are available in multiple formats, including blocks, sheets, wire-cut, and CNC-cut options. Its EPS packaging solutions cater to a diverse array of needs, including packaging for aluminum products, heavy items, jars, bottles, and artwork. Its distribution network spans over 100 shipping locations.
Professional Plastics, Inc. (PPI) is an American supplier of industrial plastic parts that was established in Fullerton, California in 1984. The company primarily offers plastic films, sheets, tubes, and rods. These are fabricated from various plastic materials including acrylic, PVC, and ultra-high-molecular-weight (UHMW) polyethylene, as well as branded plastic compounds like Techtron and Plexiglass. Its supplied parts are commonly used in the manufacture of goods such as medical trays or tools, scuba diving equipment, and panes for golf cart windshields. PPI serves clients in a wide range of industries, including in the construction, marine, and food processing sectors.
Alanto Ltd. was established in Walsall, UK, and is a manufacturer of foam and rubber products for body armor, domestic appliances, electrical and lighting, heating, and ventilation Industries. The company uses raw materials such as neoprene, polyethylene foam, solid rubber, and silicone to make the following products: rubber coils, rubber gaskets, foam tapes, foam rolls, and rubber seals. The applications of the equipment include safeguarding machines from dust and water and combating operatives.
C.B.Frost & Co. Ltd is a manufacturer of plastic that is headquartered in Nechells, Birmingham and was founded in 1921. The company manufactures rubber and plastics, specializing in materials such as rubber, sponge, cork materials, foam, and plastic. The target market of the company includes major market industries, original equipment manufacturers (OEMs), and small and medium enterprises (SMEs). Such in the major industries are rail, lighting, HVAC, MoD, and the medical market. The company provides capabilities from die cutting, adhesive laminating, high speed gasket cutting, and machined plastics. Whilst, the product portfolio category includes strips, gaskets, sheeting, and washers.
The Rubber Company, established in 2013 and headquartered in Romsey, Hampshire, is a British manufacturer and supplier of rubber products. Some of the company’s products are rubber and polyvinyl chloride (PVC) extrusions used for sealing, noise control, vibration control, and decorative trim. Product variants include seals and extruded rubber profiles, flame retardant neoprene and silicone, conductive extrusions and coatings, as well as miniature profiles. These products find applications in various industries such as automotive, construction, engineering, marine, and lighting. Additionally, The Rubber Company offers specialist products like anti-slip flooring and mats used in agricultural, commercial, gym, residential, and leisure settings.
Trocellen is a Troisdorf, North Rhine-Westphalia based German manufacturer of foam products that was established in 1972 as a joint venture between Montedison and Dynamit Nobel. The company’s product portfolio includes cross-linked polyolefin (PO) foams for sporting equipment, polyethyline (PE) foams for insulation or packaging, various adhesive tapes, and waterproof sheets for roofing applications. It also offers contract manufacturing services for unique customer projects. The company is certified to ISO 9001, ISO 14001, ISO 45001, IATF 16949 and EN 9100 standards, and has been operating as a subsidiary of Japan’s Furukawa Electric Co. Ltd. since its acquisition in 2010.
FOAMLAND SL is a Spanish manufacturer of foam and plastic materials that was established in Sabadell, Barcelona in 1998. The company’s product lineup includes foam and plastic bags, envelopes, boxes and tubes, as well as bubble, paper, and foam wraps in various dimensions. It also offers cardboard and craft paper rolls, edge protectors, and stretch films. Aside from packaging products, the company also provides technical materials including polyethylene (PE), polyurethane (PU), and polystyrene (PS) foams.
Canlar Mekatronik is an ISO 9001-certified manufacturer of textile machinery established in 2014 and based in Tekirdağ, Turkey. The company offers fine dyeing machines for delicate operations such as dying yarn or fibers, as well as standard models for dyeing fabric samples or entire beams of fabric. It also offers specialized dryers for relaxing and equalizing the tension in fabric, balloon squeezing machines for removing excess water from fabrics, and slitting machines for cutting fabric. The company primarily serves clients in the fabric and yarn manufacturing sectors, as well as in the textile industry.
Marko Foam Products Inc., founded in 1961 with headquarters in Salt Lake City, Utah, USA, is a manufacturer of foam and packaging solutions. The company's foam product line includes expanded polypropylene (EPP), expanded polyethylene, expanded polystyrene, and polyurethane (PU) foams, as well as various products including medical packaging, insulated containers, foam edge protectors used for packaging appliances, and surfboard blanks. The company serves various markets, including medical device manufacturers, pharmaceutical shippers, automotive, ESD materials, and watersports.
Atlas Molded Products, founded in 1965 and based in Byron Center, Michigan, is a manufacturer of molded polystyrene products used in construction, packaging, and OEM applications, such as engine blocks and crankcases. The company also offers fabricated and custom polystyrene products by working with the customer in designing, customization, and testing the products to meet their specifications. Products manufactured by Atlas Molded Products are third-party tested, certified, and listed with Underwriters Laboratories (UL), ONNCCE, ICC-ES, and Factory Mutual.
Shiva Metal Enterprises, established in 2019, is engaged as a manufacturer and exporter of insulation material and related activities. The company's registered office is situated in the indian newly made state's capital Hyderabad, Telangana. Their major activity involves manufacturing, particularly in the domain of professional scientific and technical activities. Classified as a Micro enterprise, Shiva Metal Enterprises commenced its operations on the same day it was founded. Their offerings include a range of products like perforated sheets and Nitrile rubber. They also make Glass Wool, LRB Rockwool Mattress, Non Woven Carpet, Fiberglass Tissue Paper, Waterproofing Service and much more.
Tavishi Enterprises, established in 2012 and headquartered in Delhi, India, operates as a manufacturer and supplier, specializing in disposable paper products, packaging materials, and packaging machines. The company's product range includes the automatic cup sealing machine, continuous band sealer, LLDPE stretch film roll, shrink wrapping machine, polyolefin shrink film, and more. These products find applications across diverse sectors, including restaurants, fast food establishments, bakeries & sweet shops, veterinary clinics, home furnishing, and related.
Piedmont Plastics, a company established in 1968, based in Charlotte, North Carolina, USA, is a distributor and supplier of plastic sheet, rod, tube, and film products. The company provides various products such as cast acrylic, aluminum composite material, HDPE, marine grade PVC foam sheet, and many more. These products are used for various applications such as signage, oil and gas, graphics, food processing, marine, and others. It also offers services such as cut to size, fabrication, film conversion, and sustainability and is loyal to excellence and customer satisfaction.
Al Najah Packing Tr, established in 2020 and based in Sharjah, United Arab Emirates, is a supplier of packing and packaging materials. The company's range of packing and packaging materials includes stretch films, air bubble rolls, carton boxes, corner edge boards, and various other packaging products. These products are applicable in various sectors, including retail, waste management, healthcare, pharmaceuticals, logistics, and shipping. The company provides customer services, including product sourcing, customer support, ensuring product availability, and offering a product catalogue.
Ranking as of December 2024
Derivation Method| Rank | Company | Click Share |
|---|---|---|
| 1 | Alta Max LLC |
7.1%
|
| 2 | Monmouth Rubber & Plastics Corp |
6.3%
|
| 3 | Drew Foam Co, Inc. |
6.3%
|
| 4 | Atlas Foam Products |
6.3%
|
| 5 | Premier Protective Packaging |
6.3%
|
| 6 | Polyfoam LLC |
5.4%
|
| 7 | American Foam Products |
4.5%
|
| 8 | Plastic Technology Inc |
4.5%
|
| 9 | Universal Polymers Corp. |
4.5%
|
| 10 | Professional Plastics, Inc. |
4.5%
|
Derivation Method
The ranking is calculated based on the click share within the plastic foam page as of December 2024. Click share is defined as the total number of clicks for all companies during the period divided by the number of clicks for each company.Number of Employees
Newly Established Company
Company with a History
*Including some distributors, etc.
*Including some distributors, etc.
| Country | Number of Companies | Share (%) |
|---|---|---|
|
United States of America
|
21 | 70.0% |
|
United Kingdom
|
3 | 10.0% |
|
Germany
|
1 | 3.3% |
|
Spain
|
1 | 3.3% |
|
India
|
1 | 3.3% |
Canada
|
1 | 3.3% |
China
|
1 | 3.3% |
Poland
|
1 | 3.3% |
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