Polyformes Ltd - Foam Inserts, Waterproof Cases

Polyformes is the UK and Europe's largest and most advanced foam solutions provider, converting and supplying Plastazote foam, Ethafoam, Stratocell and Microlen foams.

As well as supplying Plastazote sheets and blocks, our foam packaging conversion plant offers cushioning foam inserts, foam protection and foam engineered parts for all industries. We are also the UK's biggest supplier of Explorer waterproof cases and have a purpose specified warehouse to hold our large stocks of the complete range.

Explorer Cases can be supplied either with routed or water-jet cut foam inserts or empty as required. We specialise in CNC foam routing, Plastazote & Evazote foam laser engraving and thermoforming, water-jet cutting, fabric-to-foam lamination and a complete design and solutions answer for the spectrum of industrial and commercial users of closed cell expanded polyethylene foam.

Packaging is a term that usually refers to the method of housing products and items either for storage, transit or display. It goes without saying that with so many industries producing a myriad of items, from the tiniest up to the gargantuan, a range of packaging solutions must be provided.

Here at Polyformes as an example, we are able to provide tiny plastic cases with small foam pads inside for holding coins, chips, mini-meters etc, made to measure cartons with foam end caps, cradles and shapes for cushioning and support, crates with heavy duty foam to hold engines during road, sea, rail and air transit. Whatever the size, Polyformes can usually package it. Not only do we package your products but we can design the packaging too if you are unsure of what you require.

For protection, pricing, service and satisfaction, let Polyformes make it easy for you. Call us any time on 01525 852444 or e-mail sales@polyformes.co.uk

Foam inserts perform a triple duty - they cushion and protect your equipment, they allow for a complete set of equipment to be easily and quickly utilised, and they add value. We produce thousands of foam inserts of various sizes. These are fitted to cases, tins, wooden crates, ply and batten boxes, cartons, cabinets - whatever is required to fulfil the function and ensure your products are safe and attractively presented.

The closed-cell foams are available in a range of densities from 15kg/m3 up to 300kg/m3 so no matter what weight of the parts, the foams are suitable for every occasion. They are also available in colours (in the mid-range densities) to enhance your kits and also to show if a part hasn't been returned to it pocket. This is invaluable when it comes to tool control where maybe an air-craft, ship or Formula 1 racing car relies on the right tool for the right job.

Are these the most rugged cases in the world?

They come with a lifetime replacement guarantee and as yet we haven't replaced any. IP67 water and dustproof, they seem to be able to withstand all extremes and conditions whether a war zone, on a North Pole expeditionary trip or accidentally dropped in sewage plants in Swansea (no ingress, no damage, only a slight whiff until hosed down!)

Explorer Cases are available in a standard range of 24 sizes. Other sizes can be supplied depending on quantity and size.

We stock Explorer accessories including the backpacks, combination and padlocks, pick n' pluck foams, panel rings, shoulder straps etc.

Adapting the cases to allow for external plugs, switches and electronic connections is a service we offer.

The beauty of expanded polyethylene foam is that it is firm yet flexible, light in weight, easily machined and very versatile in both how it can be processed and what can be made from it. Foam shaping allows the material to be used in the most awkward places as packing pieces, buoyancy components, filler pads, cushioning blocks etc.

With PE (polyethylene) foam there is no need for an outer cover as the foam is durable enough without. It is not like the PU foam (polyurethane) which is often easily discoloured, tears easily and soaks up liquids because of its open cell structure.

Our polyethylene foams have been used in every conceivable industry from flesh colour comfort pads within bras to expansion joints in the Olympic Stadium. If you want a foam shape, ask Polyformes to quote.

We stock and convert closed cell expanded polyethylene foams - cross-linked and non-cross-linked.

These include Plastazote, Evazote, Zotek, Ethafoam, Stratocell, Microlen, Alveolen and some others.

As the UK's largest foam converter, we keep the vast majority of all of these makes in nearly all of the densities and colours on site ready to process the blocks and sheets as required.

Working a 24 hour triple shift system enables us to turn around large volumes of machined and shaped parts as well as sheet and cut pieces.

We forward order raw materials up to a year ahead in order to ensure continuity of supply.

Polyethylene foam is widely used throughout the industrial world for a whole host of purposes. The image shows an inner foam insulation set for cryogenic purposes.

On a more 'regular' basis, our foams are used greatly in the automotive field, in fact, any factory producing products that either move down an assembly line, or that are moved around the industrial plant. This is where tote trays and dunnage come into their own. Dunnage is the name for the materials used in holds and containers to protect goods during movement as well as from contamination, mechanical damage etc.

Tool control trays and drawer inserts in dual colour non abrasive foams ensure tool selection is correct and tools are returned to the same station for optimum efficiency and security.

It is not surprising that highly attractive soft touch foams are used extensively in the promotional and design industries. They really do enhance product launches and corporate promotions. With a range of colours and hardness qualities available, they are the perfect material for fancy boxes, plastic cases, tins or simply their own within an acetate or acrylic sleeve.

Retail is another market that uses large amounts of foam for display purposes, wither as a window dressing, forms of signage or point of sale stands.

Promotional products have been manufactured at Polyformes for French Connection, Standard & Poors, Levis, Nike, Sennheiser, Adidas, Bentley, Jaguar and many more. The high quality of the foam is part of the representation of the high quality of the end product or service.

Plastic Cases is a "cover all" term for a large range of various styles and sizes of carry case, promotional case, gift door kit box. These ranges in size from business card dimensions up to large attached case ranges which means all forms of products can be housed.

Again, all industry and commercial sectors utilise our plastic cases for example:-

• Instrumentation, precision parts
• Lenses, microphones, imagers
• Medical, pharmaceutical and dental equipment
• Tools and machine parts
• Advertising, promotion, stationery
• Water, gas and environmental utilities

Both of these markets are very demanding in terms of quality, supply, standards and development. The criteria in both industries are similar. In commercial and military aircraft, internal flame retardant foams and high temperature materials are a standard requirement.

Tool control is vital in both industries. Both industries use the Explorer waterproof rugged cases and the small parts plastic cases.

LD45 Plastazote is a military foam which is recognised the world over for its stability, superb cushioning and protective properties. At Polyformes we are able to process this foam material into all types of products including missile cradling, ammunition box inserts, cone supports etc. In the defence world both Plastazote and Ethafoam materials are used as packaging, support, and sleeping mats.

Polyforme's personnel are foam engineers. Designing, constructing, shaping a block or a sheet into a useful product or finished item that is functional and aesthetically pleasing.

The image shows a hinged flush-fit lid on a curved dual colour Plastazote foam base made from three different densities.

Our technical foam skills and services allow us to apply our experience and knowledge to any foam requirement and to offer a solution to projects and problems across all industry sectors.

With a dedicated Technical Centre coupled with an Engineering & Research Department, we continually strive to push the boundaries in foam developments.

What sport doesn't use foam! Okay, tiddlywinks possibly but for so many sports and leisure activities there will be foam used somewhere; an EVA foam layer in footballs, cross-linked foam in saddles, PE foam in rugby post protectors, foam skins in archery butts.

We make -

Swim floats, pool rafts and play boards
Hockey goalkeeper protection - shin pads, chest protectors
Yoga, gym and Pilates mats
F1 tool trays
Aqua sport products
Foam quoits
Flume mats
Cycle seats and supports
Shin pads, cricket pads

Foam for medical use must be of a high quality, soft touch, skin-friendly and capable of being processed easily to suit the specific medical need.

Plastazote advanced foams suit these requirements perfectly. They are latex-free, non-toxic and hypoallergenic

Polyforme's medical foam is lightweight and durable too, they tick all the boxes. Their resistance to chemicals, lotions and fluids is world renowned.

Non-toxic and safe, Plastazotes and Evazotes allow for direct skin contact whether as a finished brace, splint or support and actually during "direct to body" moulding whereby the foam is heat-formed around areas of the body.

Being cross-linked and stable, the Azote foams (Plastazote and Evazote) can be thermoformed using a combination of heat and pressure.

Azote is the brand name for a family of foams which include Plastazote, Evazote and Supazote, all made in the UK and shipped around the world.

Our closed-cell, expanded polyethylene is available in a range of densities and colours for all applications. Polyformes are converters of these materials (and other makes of polyethylene), processing them a variety of different ways in order to provide a foam part or solution.

Zotek materials are closed cell foams based on Kynar PVDF in the caser Zotek F and based on polyamide in the case of Zotek N.

Zotek F has exceptional fire, smoke and toxicity performance and is used in the aerospace, chemical, pharmaceutical and semi-conductor industries.

Zotek N is excellent for under the bonnet automotive applications with its high-temperature performance (170 C maximum operational temperatures) and its tolerance to hydrocarbons, oils and brake fluids.

As flexible foam solutions providers, we are geared up to process raw materials from scratch to the highest finished levels as required.

Our investments are based around current and future foam conversion potential and development.

As well as investing in foam conversion and bespoke machinery, we also invest in setters, operators, programmers and R & D Automated machinery is a joy, but automated machinery with experienced and professional personnel to add their input and knowledge is our advantage.

We build many of our machines in-house in order to be able to achieve final requirements.

As suppliers to many of the UK's most demanding and prestigious companies, it is important that they have the confidence in our capability from the design and development stage through to testing and trialling and ultimately to production and delivery.

ISO9001 certification is a good base standard but direct approval from large or precision companies is also a must when dealing with important contracts. We pride ourselves in being able to show our standards and capabilities to the quality audits undertaken.

Whatever your foam, case, carton or packaging requirements, please do call us if you need assistance. We are here to help and guide if are not quite sure what you're after. For any technical data, health and safety information or general queries, please call or e-mail us for a swift response.

E-mail: info@polyformes.co.uk
Tel:        01525 852444
Fax:        01525 850484

Address:

Polyformes Ltd, Cherrycourt Way, Leighton Buzzard, Beds, LU7 4UH