Industry Innovation: Dissolvable Foam

There's a huge range of considerations when developing packaging and other protective materials. The culprit that springs to mind is plastic, both single-use and recyclable, which has caused havoc and, as a result, encouraged considerable innovation across the plastics and packaging industry.

Recycling and reconstituted foam

Although foam is considered a more environmentally friendly material, the industry is still spearheading new ways to reuse, recycle and repurpose it. Most commonly, foam is broken down into small parts known as "crumb" and re-compacted into a new grade called reconstituted foam. Widely available and popular with those seeking a cheaper alternative, it still maintains the same quality and durability as newly made foam.

Dissolvable foam packaging

A new innovation launched in the US involves foam packaging that dissolves in water. Researched and launched by US-based food supplier Perdue Farms, this foam insulation packaging keeps products cold and protected, and with corn-starch as its underlying component, it can be composted or disintegrated under water and rinsed down the drain. It's further shielded from moisture by a recyclable plastic wrapper, so while not entirely plastic-free, it's an excellent step towards addressing the problem of foam packaging – though an industry-wide hurdle remains over how best to protect perishable goods without plastic.

Mechanical vs chemical recycling

Other innovations are under way to further reduce foam's impact. There are two main recycling methods: mechanical recycling reuses foam in its polymer form – breaking it down and reconstituting it into "crumb" – while chemical recycling uses several stages to break foam back into its chemical constituents. Textile scientists and chemical engineers are working closely to streamline the process and make chemical recycling even more environmentally friendly. As being green rises up company agendas and consumers grow more carbon-conscious, we can expect more foam and textile innovation, especially as governments look to impose significant sanctions on companies that don't follow guidelines. Our guides to chemical recycling of polyurethane foam and eco-friendly packaging foam explore this further.

eFoam is a proud leader in the industry's efforts to become more sustainable. We offer customers reconstituted foam products available cut to size, shape and thickness, just like a brand-new product, and we're pleased that no foam is sent to landfill during production – all our offcuts are reconstituted.

To read more on eFoam's environmental efforts, take a look at that page. Or, to discuss an environmentally friendly foam option tailored to you, please contact us.

Frequently asked questions

What is dissolvable foam?

A corn-starch-based foam insulation packaging, developed in the US by Perdue Farms, that keeps products cold and protected and can be composted or disintegrated in water before being rinsed down the drain. It's shielded from moisture by a recyclable plastic wrapper, so it's not entirely plastic-free.

How is foam recycled?

There are two main methods. Mechanical recycling reuses foam in its polymer form – breaking it down and reconstituting it into "crumb" – while chemical recycling breaks the foam back down into its chemical constituents in several stages.

Is reconstituted foam good quality?

Yes. Reconstituted foam is made from foam broken into "crumb" and re-compacted, and despite its lower cost it keeps the same quality and durability as newly made foam. At eFoam, all foam offcuts are reconstituted, so none go to landfill.