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How Foam-in-Place Packaging Helped to Increase Internal Product Protection and Improve Productivity

Case Study: Manufacturer


Crawford Packaging was contacted by a Client who manufactures aviation equipment. They were experiencing damages to metal parts during internal processing and transportation. The damage to these parts was extremely costly and was impacting the Clients productivity levels. As the damaged parts arrived, the part would have to be assessed by an employee before any repairs could be done or new a replacement was sourced.

Crawford’s Packaging Specialist worked with the Client to find an effective, in-line packaging solution that was easy to operate and could be used to pack a variety of packaging applications. The new packaging solution eliminated the internal damages the client was experiencing, reducing costly damages and increasing production efficiency, increasing their profitability.

Red Planes in Blue Sky Performing Air Show

Damaged product icon on top of blue kraft paper background


Due to the precision and delicacy of their aviation equipment, the Client was experiencing damage to their small and medium sized components during internal processing. Parts were often arriving to their installation station damaged. Employees were then having to either fix the damage when possible, or source a new part before being able to continue the installation process. These delays resulted in slowdown of the assembly process and a decrease in productivity.

The Client was in need on an in-line packaging solution that would give the fragile components added protection, allowing them to arrive at their installation stations undamaged.

Protective Packaging Solution Sealed Air Foam-in-Place System for Aviation Equipment 


Having analyzed the customers issue and the types of sensitive parts that were being damaged, Crawford’s Packaging Specialist recommended the Client consider the addition of a Foam-In-Place packaging system from Sealed Air. These advanced packaging systems offer a variety of methods to create custom foam molds that lock parts in place during the shipping process. These molds securely hold their products in place while providing a strong, protective shell for the product packed inside.

Intrigued by the innovative packaging solution, the Client met with Crawford’s Packaging Specialist for a product demonstration at Sealed Air’s product testing facility. Prior to the product demonstration the Client sent advanced product samples to Sealed Air’s Packaging Design Lab. At the Design Lab Sealed Air tested the Client’s products strength to determine the right foam density for their products. This allowed Crawford Packaging to develop a complete turn-key solution with accompanying Pack Value Analysis for the Client’s consideration. 


At the demonstration, the Client was introduced to the Instapak Foam-In-Place packaging system. These efficient foam packaging systems use A and B liquid components that are combined together through an easy to use self-cleaning dispensing system. Operators place a layer of a strong, Instapak PE Flim in the bottom of the carton they will be using for shipping. The packer then pours a layer of foam onto the film. As the A and B water based urethane components mix, they react, increasing their volume by up to 280% before hardening into a solid piece. As the foam rises, the employee folds over the Instapak Plastic Film to create the first level of the pack. The fragile part is placed in the box on top of the folded plastic liner. As the foam continues to rise, it expands around the part filling any void space. A second piece of Instapak Plastic Film is then placed over top of the part, and the process is repeated to form the upper shell.

Having been able to get hands on experience with the Instapak Foam-In-Place packaging system, the Client was confident this was the packaging solution for their business. Due to the volume of parts that would need to be packed with Instapak, the Client chose to add the Instapak 901 to their inhouse packaging operations. The Instapak 901 is designed for high volume packaging solutions and uses a variety of A and B foam reservoir sizes to maximize floor space and performance. A and B foam components are available in 15 Gallon cubes, 55 Gallon Steel Drums or 275 Gallon returnable and reusable totes. The system is designed to use minimal floor space while offering maximum packaging versatility.


This knowledge based packaging solution has helped the Client improve their internal part handling process by eliminating costly part damage during transport. This improvement has been vital in helping their assembly operations achieve high productivity levels and improving their overall cost by decreasing breakages and reducing assembly downtime.  The Client found the Instapak 901 Foam-In-Place so effective they are now using the Foam-In-Place system to package parts that are being mailed to customers.

This reduction in material would help the Client save an additional $5 per box!

With the added strength and support provided by the Instapak Foam’s protective shell the Client is now able to re-evaluate the corrugate cartons they use. Currently the Client packs all of their parts in a triple-walled corrugate box. This thicker box uses more raw material to create a more resilient box. The increased protection provided by the Instapak Foam-In-Place system is now making it possible to downgauge to a two-walled corrugate box. This reduction in material would help the Client save an additional $5 per box packed.

Crawford Packaging is a full-service packaging company located in London, Brampton and Waterloo, Ontario. From packaging to packaging equipment, installation and upgrades, and in-person equipment training and repair, we're focused on your business success every step of the way.