Zouch Converters Ltd

Open-cell foam has many qualities that make it the perfect candidate for low viscosity (water-like) liquids that need to be applied for even and comfortable coverage. Open-cell foam acts as a filtration foam that is highly moisture absorbent and breathable, so that the open-cell foam allows air and liquid to pass through to be absorbed. That means that liquid is slowly released as the foam is worked against a surface.

It allows for low viscosity liquid products to be easily 'sponged on' and offers versatile coverage, as the liquid slowly penetrates through the sponge's open cells. The foam's soft, pliable surface means that streaks aren't left on characters and the slow release of the liquid stops larger quantities of product from being wasted.

The concept is to allow consumers to apply a wide range of skincare products to their skin; without using their hands. This includes sunscreen; fake tan products, mosquito repellents, moisturisers, pain relief gels etc. The market is now trending in this direction and there are already inferior products in the market currently fulfilling this function.

Our open-cell foam is hypoallergenic and can be exclusively designed to contact even the most sensitive skin. They're also straightforward to clean, non-swelling and durable for long-lasting use.

Different densities of open-cell foam can be joined with adhesive to create layers and levels for liquids to pass through. This can be especially handy for products with two types of liquid (often within the cosmetic industry) to be distributed simultaneously with a push of the outer casing. It allows for a lower viscosity liquid to be expressed more freely than a thicker liquid, where less product or coverage is needed.

This type of liquid application is becoming more and more popular within the beauty and cosmetic industry. Whereas before it might have been more widely used for cleaning products, such as shoe cleaning and waterproofing, the slow release of product through sponge allows for more flawless and streak-free application for cosmetics too.

With brands like Maybelline using sponges in their famous 'Instant Anti Age Eraser Concealer' and Benefit Cosmetics turning to sponge for their 'Watt's Up' highlighter to blend for a luminous sheen, it's no surprise that open-cell foams popularity has increased ten-fold in recent years. We wouldn't be surprised to see brands turning to sponge applicators already applied to foundation bottles, instead of blender sponges in the next decade.

If you have a new project or challenge when it comes to open-cell foam and sponge to apply liquid, no matter the industry or complexity of the applicator, our expert technical team are on hand to offer unbiased advice.

Our open-cell foams come in grey, white or black as standard, but can be custom made in a range of colours such as: blue, yellow, green, violet and red, or even different skin tone shades. They can be cut and formed to the shape and size you desire. We offer environmentally friendly, hypoallergenic, quality foam products to suit all sectors of the cosmetic, beauty and personal care markets.

Get in touch with our expert team to discuss your specific application, and we will support you from prototype to customer-ready product, as well as sending out samples of foam to ensure you're happy with your final application.