Zouch Converters Ltd

Jewellery is a very personal item and can be both inexpensive and costly, but that doesn’t make it any less meaningful to an individual. When it comes to protecting jewellery in packaging, especially at the higher end of the spectrum with more extravagant items, it’s important to keep the craftsmanship of occasion wear preserved. It’s essential to secure jewellery items in place without them slipping around easily or becoming loose and amassing damage.

We recently worked with a high end jeweller who needed to keep their light-weight chain jewellery protected for transit during the gifting period. We advised the use of our closed cell cross-linked polyethylene foam, with its smooth surface and well distributed, independent closed cell structure.

Benefits of our Closed Cell Cross-Linked IXPE Foam

Odorless

The foam itself doesn’t let off any odor nor does it absorb smells. If the foam is being used for display purposes or for presenting to potential custom, retailers can be rest assured there will be no bad odors from the foam itself and men’s and women’s parfums won’t pass onto the foam either.

Mould and stain resistant

Our IXPE foam has been irradiated by a high energy electron beam, meaning the foam is protected and defends against the growth of mould and bacteria, as well as not transferring colour to the packaged product.

This makes the cross-linked polyethylene foam a favourable material for packaging inserts when it comes to precious items such as jewellery, which may be both displayed and stored for long periods of time. Our closed cell polyethylene foam is UV resistant, chemically inert and non-toxic.

Durable and shock absorbent

The independent, closed cell structure of our IXPE foam makes it especially compact and robust, which means that it doesn’t crumble or go brittle over time. It can withstand handling well and is shock absorbent, making it a choice material for transit.

High strength to weight ratio

Our eFoam is lightweight but incredibly strong to combat against any wear and tear. It’s especially good for transit, keeping delivery and shipping costs low due to its weight compared to other foams.

Colour and flocking

Whilst most jewellers stick to standard black, grey and white, our eFoam is available in a range of colours if something bespoke is needed. We’re also able to flock foam if a more velvety surface is favourable to add a touch more luxury to packaging inserts. Due to the foams consistent cell size and structure, it also makes for a much more aesthetically pleasing foam.

Hypoallergenic

As foam is likely to be touched or in contact with items that will be worn against skin, we’ve ensured that our foam is entirely skin friendly and hypoallergenic.

Despite its high quality structure and material benefits, our closed cell cross-linked foam is very cost effective. We can split, saw, rout, die cut, water-jet cut, butt-weld, laminate, adhere, thermoform or compression mould all of our foams to create even the most complex shapes and sizes. As well as ensuring bespoke inserts within the foam for items such as business cards.

Whatever you’d like to achieve, our expert team can work with you to design and develop products and components, choosing and using the very best materials for the job. Get in touch to talk to use about your latest challenge and our unbiased team will be on hand to offer advice.

Our filtration foams are widely used within the aquatic industry, whether for at home aquariums or large scale commercial aquariums and ponds. There are many types of aquarium filters that are available on the market, each with their own specific set of attributes dependant on the size of the aquarium and the filter size needed to keep it clear.

Mechanical filtration

Mechanical filtration allows water to pass through the filtration foam and catches particles within the water to remove them from an aquarium environment.

Chemical filtration

Chemical filtration aims to specifically target excessive amounts of nutrients or chemicals within an aquarium environment.

Biological filtration

Biological filtration is heavily dependant on the amount on the size of an aquarium and the amount of space available for bacteria to be able to grow. Biological filtration breaks down different types of bacteria through the nitrogen cycle (waste, food and fungi), which then creates ammonia which is toxic for an aquariums inhabitants.

The most commons of basic setup filters is a sponge/air driven filter which use open cell foam. This type of filtration foam is commonly used for aquariums found in the home for small fish, invertebrates, breeding and nursery tanks. This type of sponge foam filter is powered by an air pump and forces water through the open cells.

However there are many types of filters available such as canister filters, box filters, power filters and trickle filters to name but a few. All of these types of filters use open cell filtration foam to pass the water from within the tank and through the filter, whether they’re micro, small or large-poured sponges.

Our range of filtration foams at Zouch Converters are polyurethane based with either a polyester or a non toxic, chemically stable Polyether Polyol, created by removing membranes from within through a process called ‘reticulation’.

This creates an open cell sponge which has an almost ‘net-like’ structure within the foam and allows for low flow restriction, giving particles freedom to pass through. However, dust and unwanted particles are trapped within the cells of the reticulated foam, allowing pure wanted (and wanted bacteria) to pass through the filtration system and back into an aquarium or ponds environment.

We specialise in high-performance products from worldwide manufacturers meeting International standards and solving our customers needs with a wide range of materials choices. By providing an extensive range of foams and material types, Zouch can easily satisfy many complex needs efficiently and quickly.

Whatever your need, get in touch with our technical experts and we’ll be sure to filter through all your worries and find a solution to your upcoming project.

Foam is an incredibly lightweight, flexible and durable material which makes it perfect for props, costume design, scenery, armour and weaponry, whether that’s for film or theatre props or for personal foam costume construction. EVA is one of the most popular forms of closed cell foam for such applications and has an affordable, low cost price point considering the high quality form of the foam itself.

The foam used for costume construction is not unlike the foam used for exercise mats or camping mats depending on the thickness used and there are two types often found for foamsmithing, costume and set construction.

EVA / Closed Cell Foam

One of the most resistant and denser of foams, EVA / Closed cell foam comes in a range of different thicknesses, densities and colours, as well as being made available in rolls, sheets and blocks. Closed cell foam has a smooth surface and due to its nature, its cells are compact, making it much denser and considerably more waterproof, which can be of great benefit for scenery and set design that will encounter changing weather conditions.

Closed cell foam is also known as craft foam, however, craft foam is usually thinner and used when a more flexible material is required for better dexterity and movement in costume or for larger surface areas in set design.

Open Cell Foam

Open cell foams are much softer, somewhat spongier and lighter than EVA foam. Open cell foam is used for less rigid construction or for areas that need to be more padded or give greater flexibility. It’s breathable, soft, moisture absorbent and hygienic.

Our open cell foams come in grey, white or black as standard, but can be custom made in beige, blue, yellow, green, violet and red. We can supply our open cell foam in sheets, rolls and shaped to your specific needs.

Our technical foams have several key benefits for those in the prop and costume industry:

• Smooth on both sides but can easily be manipulated for texture with tools, such as sanding for 3D realism. It also cuts and scores easily (can also be cut with a hot wire).
• Our closed cell foam is easy to seal, prime and paint (less so with open cell as that’s moisture absorbent).
• Dense and comes in a variety of thicknesses and can also be glued together.
• Flexible, lightweight, strong and tear resistant.
• Shaped with ease once heated.
• Waterproof (closed cell)
• Non Toxic and Safe
• More durable than some foams
• Easily joined together with a heat gun or a glue gun

Here at Zouch, our highly advanced technical foams are trusted by professionals across the world. They deliver smart, specialist benefits at a competitive price, while we deliver a customised, consultative service, fully focused on what you need – from the most effective materials on the market to a bespoke product created just for you and your business.

Provision of samples

We offer a closer look at our product ranges by supplying free samples, as well as project advice. Get in touch with our expert team for more information about free samples of our closed cell foam.

Our technical team can work with you to choose the best material for any design, so you can more effectively develop the props and costumes you’re looking to create. We can split, saw, rout, die cut, water-jet cut, butt-weld, laminate, adhere, thermoform or compression mould all of our foams to create even the most complex shapes and sizes in preparation for your project. Simply contact us today to speak to one of our experts.

Eliminating background noise when it comes to studio recording is key and for those using quality condenser microphones, any and every sound in and outside of the environment becomes a troublesomely obvious sound. That’s when the age old question is asked; is soundproofing really a necessity? And it’s swiftly followed with a resounding yes.

Soundproofing ensures that unwanted noise created in environments outside and inside of a recording studio are cancelled out. That could be from the proximity of a neighbouring office or classroom, as well as the obvious sounds from the loud to the quiet whir of computer equipment within the studio itself.

Although the basics might have been covered, such as giving an ample distance between studio hardware and exterior rooms, laptop stands, cushioned flooring, studio racks or if your budget allows, a separate recording room to the studio, noise reduction is often still an issue that remains unsolved without physical soundproofing.

Acoustic foam is an absorbing material that keeps noise under control and dampens sound by reducing the echo that is being absorbed from object to object. This reduces the audible sound within the room, however, acoustic foam needs to be considered to counter the sound from exterior rooms too.

Sound absorption materials aren’t just used for recording studios, but make for a brilliant solution for noise reduction in concert venues, theatres, cinemas, schools (lecture theatres, classrooms, music rooms), conference rooms in offices, etc.

At Zouch, our foam is soft and lightweight, easily allowing echo to be absorbed into the foam material by softening the surfaces of the environment. The open cell foam absorbs sound as it passes through the material and in turn, converts the sound to heat over echo. Acoustic foam is easily installed and affordable, and can be created in convoluted patterns or adhered with fabric dependant on the desired aesthetic.

Depending on your specific project, we can develop any acoustical absorbing material to your needs. Easily cut and installed, our products come in a whole range of formats, including sheets and rolls – with or without punched components, contoured cuts and special impregnations.

Our technical team can work with you to choose the best material for any design, so you can effectively control noise in your working environment. Get in touch with your challenge and we can help choose the right absorbing foam material for your environment.

It might only be April but sure enough, that time of year will come around when we need to consider packaging styles and protection for those all important gifts during the Christmas period. There’s nothing worse than taking the time to venture through the crowds or endlessly scroll online to find that special something, only to receive the item damaged before gifting or worse, to gift and then find the present broken.

When it comes to packaging it is key to ensure that the surrounding foam is strong enough to withstand any potential knocks during transport, whilst keeping the item steady and intact. It’s especially important when it comes to fragile items such as glassware and protecting it from cracks and leakage.

The most popular choice of foam within packaging for our customers at Zouch is Closed Cell Polyethylene Foam as PE foams offer many benefits in ensuring safe arrival for the protected items.

Benefits of Closed Cell Foam for Packaging

Vibration and impact dampening

Closed cell foam is often used for its vibration and impact dampening qualities for fragile items that require protection during transportation, storage and contact. PE foam comes in a range of densities but it’s non-abrasive and makes for a soft surface for contact with delicate items.

Easily backed with adhesive

Adhesive backing can be added to polyethylene foam so that it can be easily joined with other materials, such as display boxes, to keep the foam in position for continual use and transportation.

We recently worked with Bread and Jam using closed cell foam to safely secure their beautiful personalised gift with adhesive backed foam.

Lightweight

Closed cell foam is incredibly lightweight but that doesn’t affect its quality. It’s a low cost alternative that still offers excellent protection for secure packaging and safe transportation.

Durable

PE foam is durable in nature due to its closed cell formation. The foam doesn’t become brittle or crumble. That means that if the item is boxed for an extended period then the foam isn’t going to wear with age and adhesive will keep its stick.

Cut to any shape

Closed cell foam is easily cut whilst retaining it’s rigid form. It can either be produced in foam rolls or foam sheets or cut to specifications and designs, as well as being lasered and die cut for all manner of shapes to protect fragile items.

Whatever type of secure packaging you’d like to achieve, our expert team can work with you to design and develop products and components, choosing and using the very best materials for the job. We can split, saw, rout, die cut, water-jet cut, butt-weld, laminate, adhere, thermoform or compression mould all of our foams to create even the most complex shapes and sizes, so talk to us about your latest food application challenge.

Noise cancelling headphones have become more popular and necessary to reduce external noise for the protection of children’s hearing, especially during outdoor events such as festivals. Noise cancelling headphones protect young children’s ears from high levels of noise that could damage hearing and instead, offer a barrier from powerful sound often associated with music concerts, festivals, firework displays and even on airplanes.

Many parents and educators for school trips look to offer children more fulfilling and engaging experiences from a younger age and noise cancelling headphones mean greater opportunities for activities

Typical Decibel Chart

• 140 - Gun Shot
• 130 - Jet Taking Off
• 120 - Jack Hammer
• 110 - Fire Engine/Police Siren
• 100 - Music Concerts
• 90 - Chainsaw
• 80 - Lawn Mower
• 70 - Busy Street
• 60 - Noisy Restaurant
• 50 - Normal Conversation

There are many benefits to using noise cancelling headphones and the open cell foam associated with them that reduces the sound.

• Helps to reduce any stress that is associated with loud noise
• Increase a child’s focus from loud distractions
• Protection during a child’s development stages
• A sensory break and calming environment

Our specially developed flexible and comfort foams absorb echo to reduce and eliminate background noise by controlling the vibration that sound causes when it bounces off surfaces. Foam is a sound absorber and doesn’t control the noise directly, but improves acoustics which reduces the external noise.

We developed an advanced range of acoustical absorbing foams, designed specifically to deliver the highest level of noise reduction. With a polyurethane base and a unique open cell structure, our foam absorbs airborne sound by dissipating the energy within the cellular network.

Popular benefits of our open cell polyurethane foam for noise cancelling headphones:

• Lightweight, flexible and comfortable so they can fit against the ear and not feel heavy or bulky to the wearer
• Excellent sound and vibration dampening
• Absorbs airborne sound
• Meets today’s most demanding acoustic materials specifications
• Very durable foams so they do not break or crumble (especially considering babies and toddlers with tendencies to put items in their mouths)
• Soft, comfortable material which helps to reduce pressure around the ears
• Environmentally friendly and hypoallergenic

Depending on your specific project, we can develop acoustical absorbing materials to your needs. Easily cut and installed, our products come in a whole range of formats, including sheets and rolls – with or without punched components, contoured cuts and special impregnations.

Our technical team can work with you to choose the best material for any design, so you can effectively control noise in your working environment. Get in touch with your challenge and we can help choose the right absorbing foam material for your environment.

Rubber extrusions make for popular covers when finishing products such as furnishings, equipment and decorative trimming, as well as sealing and controlling noise and vibration. With so many different application uses, no one size fits all and we create custom made sponge extrusions for even the most demanding of projects.

We can make extrusions in a wide range of densities and hardnesses as well bespoke shapes and sizes for all manner of applications using EPDM or Neoprene Sponge, depending which material is best suited to your requirements.

EDPM Sponge

EPDM (also known as Ethylene Propylene Diene Monomer) is an expanded closed cell sponge. Its versatility ensures that it's resistant to UV and weathering and has high ageing stability. Due to its closed cell structure it is entirely water and air resistant. An incredibly flexible and resistant sponge rubber that we're able to develop in a wide range of densities, sizes, rolls, blocks, sheets which can all be applied with a self-adhesive, if required.

Neoprene Sponge

Our Neoprene Sponge Rubbers combine strength and durability with optimum resistance to ageing, weathering, UV and ozone. Neoprene is closed cell, flame retardant and made from a synthetic, polymerised chloroprene rubber.

We can also bond our rubber extrusions with adhesive backing as pictured above. This shaped tube foam has been backed with a high performance heat-activated acrylic tape to help when mounting, bonding and joining to varying materials.

Common types of applications we work with at Zouch for rubber extrusions:

• Door seals and door strips
• Edge trims
• Window sealing profiles
• Cushioning for seals
• Sound insulation
• Capping profiles
• Automotive boot seals
• White Electricals
• General sealing
• Drainage Systems
• Marine Windows

Common types industries we work with at Zouch for rubber extrusions:

• Packaging
• Retail
• Military
• Medical
• Construction
• Automotive
• Marine
• Aeropace

Provision of samples

We offer a closer look at our product ranges by supplying free samples, as well as project advice. Get in touch with our expert team for more information about free samples of our closed cell foam.

No matter the project, we have a team of technical experts at your disposal to help you choose the right material for your next innovation. From first call to the finished item, we can help you every step of the way and offer technical support and advice on the best product for your specific application or assembly process needs. Simply contact us to speak to one of our experts.

No matter how tough your kit is during climbing, hiking, expeditions and camping, it can still fall short when it comes to the elements and flora - with branches, thorns, rocks and even barbed wire easily catching and snagging waterproof jackets or trousers no matter the denier. When braving more extreme weather conditions repair kits are essential for preparing for damage on the go.

Our Polythene Coated Cloth Tape is a high-grade cloth tape with a pressure sensitive natural rubber adhesive, making it strong and hard wearing for more vigorous movements outdoors. Whilst many repair kits come with circular and square patches that can cover smaller holes, tape allows for larger tears that are more likely to leak.

Types of possible applications for repair

• Waterproof jackets
• Waterproof trousers
• Tents
• Sleeping bags
• Rucksacks and bags
• Map cases
• Airbeds

Sometimes called ‘Gaffer Tape’, Polythene Coated Cloth Tape’s pressure sensitive self adhesive backing is designed to adhere to any fabric and provide a waterproof bond with its solvent-based adhesive.

Solvent-based Adhesive

Solvent-based Adhesive can offer extraordinary chemical resistance, making them well-suited for use in environments where exposure is possible, such as the outdoors. Solvent adhesive tape can also function at low and high temperatures making them extremely versatile. They are strong and have a superior shear and peel strength.

Pressure Sensitive

As the tape doesn’t require heat, water or solvents to activate the adhesive, it means that it’s tacky at room temperature and can easily be applied by varying degrees of pressure with a hand or finger.

Product features

• Polythene coated
• Pressure sensitive self adhesive backing
• Excellent strength
• Low cost but high quality
• Thin, light material for flexibility
• Conforms to contours of fabric
• Water repellent
• Comes in black

At Zouch, we have an unrivalled range of pressure-sensitive self-adhesive tapes that are handpicked from the world’s leading manufacturers. We’re able to deliver them as reels, spools, master logs, sheets and die-cut pieces, both single-sided or double-sided.

We have an expert technical team who will give you unbiased advice and support. Get in touch with our team about your challenge and we will help you to determine the correct PSA Tape for your project. We also offer a fast and free sample service to ensure that you’re happy with the quality of PSA Tape.

In the last decade, MUAs and beauty professionals have been redefining make up application. The right texture is paramount when it comes to ensuring a smooth and flawless finish, and for a beauty conscious world, the consistency and surface of an applicator can truly make a difference in the process. That’s why foam has become more popular within the beauty industry for the application of makeup.

Open cell foam technology has seen many advances and whilst it’s cost effective on mass production, it also has a lot of benefits to the user which means that despite being low cost, it’s also high in quality.

Open cell foam

Open cell foam is breathable, soft and moisture absorbent. If the foam is sourced correctly, it is hypoallergenic and exclusively designed for contact with the skin. It is called open cell because its structure allows for air to pass through it and for liquid to be absorbed - that allows for the product or water to slowly be released as the foam is worked against skin.

Breathable and soft

The foam is low density and gives a soft, sponge like appearance. It’s breathable and is comfortable when used against skin, unlike makeup brushes which are prone to excess foundation, leave-behind brush hairs and visible strokes when not blended correctly.

Moisture absorbent

The nature of open cell foam means that it easily absorbs moisture. Whilst this might not seem like a benefit due to the foam soaking up foundation, in actuality, for a flawless finish most make up artists dampen a sponge prior to application for a smoother texture and easier release when applying.

Hygienic

Most manufacturers of open cell foam for cosmetic use will ensure that the foam is hypoallergenic and exclusively designed for contact with the skin. Open cell foams can be easily cleaned and due to the cost effective nature of production, they’re disposable.

Used for applicators for foundation, self tan and highlighters, as well as for cosmetic sponges like cleaning cellulose or those used for the body when bathing.

Bath and Body

We’re able to create bespoke shapes with our open cell foam to delight and attract consumers with items that they find relatable and appealing to themselves or a gift for another. Pictured above, we’ve created open cell bath sponges in the shape of a Scotty dog and bone for the latest line used by one of our clients.

Our open cell foams come in grey, white or black as standard, but can be custom made in beige, blue, yellow, green, violet and red, as well as marbling effects as seen below in our triangular cosmetic sponges.

Makeup application sponges

Foam is a more functional option compared to brushes and the ability to shape and mould the material, means that creative design doesn’t have to be compromised. Originally starting with the triangular wedge to the teardrop, designers have developed more and more options based on the needs and requirements of their industry, with several new shapes that offer a greater experience and finish for the user. Read more about our open cell foam applicators shapes..

These open cell spongers aren’t just for consumers - they can be used for professional application and cut and formed to any required shape, for instance, if a certain angle is required to meet a design for special effects makeup in film and television or even large sponges for set design.

Tanning mitts

Tanning mitts have become increasingly popular when applying self tan for a bronzed and sunkissed look. A mitt leaves skin with a smooth and even finish and that’s largely down to the composition of the sponge used - open cell foam.

The open cells absorb self tan liquid whilst slowly releasing it as the wearer works the mitt against the skin in circular motions. It’s much more efficient to use a mitt due to its larger surface area (when compared to a hand) and the fact it doesn’t leave self tan liquid residue on skin causing it to stain. The foam can simply be cleaned with warm water and soap too - making it a great material for at home use for beauty product consumers.

Here at Zouch, our highly advanced technical open cell foams are trusted by health professionals and beauty brands right across the world. They deliver smart, specialist benefits at a competitive price, while we deliver a customised, consultative service, fully focused on what you need – from the most effective materials on the market to a bespoke product created just for you and your business.

Our bespoke, problem-solving approach has secured exciting projects with award-winning global brands, unlocking their potential and empowering them to grow creatively and strategically.

We offer environmentally friendly, hypoallergenic, quality foam products to suit all sectors of the cosmetic market. Get in touch with our expert team to discuss your specific application and we will support you from prototype to customer-ready product.

When it comes to large data centres, computer servers generate endless amounts of heat and ensuring the reduction and cooling of the space is paramount to effective workflow and safety. The heat that’s caused by servers requires a carefully controlled environment due to the complex and highly expensive equipment used for big data. With the likes of Racks, CRAC Units, DX and Power Distribution Units, it a necessity for secure data rooms to monitor and control air flow.

The demands for cooling systems and ventilation continues to rise with the introduction of more powerful processors, increases in components that need connections to a computer network and the demand for uptime, to name but a few.

Open Cell Polyurethane Foam

Zouch’s open cell flexible PU foam is used in many types of building applications and when it comes to critical data centre solutions, it’s designed as an air barrier to seal openings. It comes in 600mm x 600mm sheets by 50mm thickness and is perforated in cubes of 25mm x 25mm for ease of adapting its shape to fit around obstructions such as cabling. It’s a low cost solution that’s highly effective and easily installed making it perfect for raised flooring in data centres.

Controls air flow

Due to its open cell structure it works to improve cooling efficiency but at the same time reducing energy costs, specifically around cabling that needs to be tidy and secure, by preventing too much airflow. Our open cell foam also has a UL94 HF1 flame retardancy safeguard to protect personnel and equipment.

Prevents dust and debris

Open cell foam significantly reduces dust, debris and allergens and is mold growth resistant. It’s incredibly important to ensure that dust and debris isn’t exacerbated within data centres and is kept to bare minimum, with incoming air being ventilated around vast data centres.

Key features for open cell polyurethane

• Soft, sponge like material for ease of adjusting around obstacles
• Low cost due to its open cell structure (thus using less material)
• Available in grey.
• Flame Retardant UL94 HF-1
• Dust and debris free
• Install in minutes without the use of any tools or fasteners
• Readily available at Zouch Converters
• Comes in tiles for ease of installation and retains its shape over many years

At Zouch, our specialist open cell foam for can perform in even the most demanding conditions. Our in-house design and development engineers are constantly focused on optimum performance and cost effectiveness, whilst ensuring fundamental safety for personnel and protection of data.

Which is why you’ll find our smart, state-of-the-art products in the interior infrastructure cooling solutions worldwide. Get in touch with our expert team to discuss your specific application and we will support you from prototype to product or we can supply our readily available solutions.

In many cases, padding used for shoulder straps or cushioning (particularly around hip support on rucksacks) is too thin and results in pads turning sideways with little need for movement or shock from the wearer.

Compounds used to create foam can be weak and more fragile than first realised, which leads to the material deteriorating sooner than expected. When used in products for retail, it can quickly discourage consumers from a brand and cause return items that would have otherwise endured long term use.

Common bag applications for strapping and padding:

• Laptop bags and cases
• Laptop strap padding
• Rucksack and backpack strap padding
• Rucksack and backpack hip support
• Baby carriers
• Crossbody bags and fabric satchels

Comfort

Comfort is one of the biggest factors in strap padding and cushioning and when it comes to closed cell foam, suppliers can rest assured that it’s soft and comfortable for the wearer whilst remaining durable. It doesn’t crumble like some foams over time and can be formed in several different densities whilst remaining lightweight. When considering the length of time and the weight that some carriers will endure throughout travel, expeditions or even through the use of a baby carrier - comfort is key.

Lightweight

Closed cell foam can be created to most sizes and shape specifications. It is extremely lightweight making it the perfect alternative for padding when weight is a consideration - for instance, baggage allowance for travel and overall weight of the bag for the carrier.

High strength to weight ratio

Closed cell foam doesn’t compress easily as it keeps its form even under pressure and its shock absorbency helps to protect the wearer during more vigorous activities, such as rock climbing and scrambling.

Waterproof

Due to its closed cell nature the foam doesn’t allow moisture to pass through but antibacterial qualities applied to the foam keep it low odour for prolonged use or for use in warmer climates.

More benefits on using closed cell foam padding:

• Doesn’t compress easily
• Soft and comfortable
• Antibacterial & Non Toxic
• High quality
• Low cost
• Durable, so it doesn’t crumble with use
• Waterproof (Closed Cell) & Buoyant
• Thermal protection
• Fire and chemical retardant
• Shock absorbent
• Variety of densities available
• Uniform Cell Structure
• Easy to convert and available in a range of sizes
• Environmentally Friendly & Safe
• UV Resistant

At Zouch, our high-performance closed cell foams and adhesive bonding tapes are trusted by specialists right across the world. Designers and engineers choose our advanced materials because of their durability, weight, water resistance and comfort.

Get in touch with our expert team to discuss your requirements and we will work with you to deliver a customised, consultative service, fully focused on what you and your product needs.

Heat exchange between two materials such as aluminium for window and curtain walling, doors and windows, relies heavily on U-values (thermal transmittance) for thermal insulation. The better insulated a system is, the lower its U-value and the better its ability to reduce heat between material surfaces and the outer environment.

Modern systems now look to use foam blocks and rolls as inserts for cold bridging and thermally efficient constructions. Many commercial and residential buildings have an energy efficiency requirement and creating thermal sections (using closed cell foam) creates insulation between inner and outer frames.

Metal systems have a tendency to let heat out and keep cold in, so cold bridging allows for areas where gaps are unavoidable to be filled with foam insulation. Without insulation, these areas are prone to being colder and have a greater risk of forming condensation which leads to mould.

Closed cell foam can be used for both insulating block work for cavity closure and lintels, as well as full cavity filling.

Areas where cold bridging occurs:

• Window and curtain walling
• Doors
• Windows
• Pitched roofs
• Flat roofs
• Flooring
• Vehicle manufacture

Closed cell foam is made up of intact, impervious cells. This gives them greater resistance to air, water and liquid leaks, helping to prevent mould and bacterial growth. At Zouch, we cross link our closed cell foam to make it much stronger, denser and heavier than the open cell variety, giving it better insulating properties (U-values), suitable for vehicles, buildings and appliances.

We can add EVA or a metallocene compound to closed cell foams to make them softer and more elastic, or use flame-retardant additives to meet demanding automotive, aerospace, electronic and building regulations.

Overview of benefits to using closed cell foam:

• Low cost
• High quality foam
• Lightweight
• Low odour
• Antibacterial
• Range of densities
• Flame retardant
• High strength-to-weight ratio
• Non-toxic
• Thermally insulating
• Resistant to UV, moisture and chemicals
• Waterproof
• Highly versatile
• Range of sizes

We can split, saw, rout, die cut, water-jet cut, butt-weld, laminate, adhere, thermoform or compression mould and cut to size all of our foams, to create even the most complex shapes and sizes. We can supply our polyethylene foam in sheets, rolls and blocks.

Whatever you’d like to achieve, our expert team can work with you to design and develop products and components, choosing and using the very best materials for the job. Talk to us about your latest challenge today and our free sample service.

Handbags are something of an essential accessory in everyday life for containing important items and have become a statement piece within the fashion industry. Although it might not be immediately obvious, foam plays an important part in the structure and stability for the posture of handbags, as well as purses, book bags, laptop carriers and nappy bags to name but a few.

Whilst some lightweight material bags use compressed fleece for their interlining and interfacing, our closed cell polyethylene foam makes for an excellent choice for ensuring the stability and structure of handbags. By giving luxury outer material a more rigid interior to hold its form, the shape and body of a handbag can be designed and styled with the confidence in its framework.

Closed Cell Polyethylene Foam (PE)

There are many benefits when it comes to closed cell PE foam and one of its most popular points, is that despite being low-cost, it’s high quality and can be produced on mass in sheets and rolls for ease of application. It’s durable and robust so it won’t crack, crumble or become brittle - allowing for the longevity to last in a more regularly used handbag and one that’s often saved for special occasions.

It’s lightweight which makes it perfect for carrying - especially in holiday luggage where weight plays a key role in baggage allowances. They come in a range of attractive aesthetics, are low odour (antibacterial) and have a high strength-to-weight ratio.

Benefit highlights of Polyethylene foam:

• Low cost
• High quality foam
• Lightweight
• Low odour
• Antibacterial
• Range of colours and densities
• Flame retardant
• High strength-to-weight ratio
• Non-toxic
• Thermally insulating
• Resistant to UV, moisture and chemicals
• Waterproof

It’s not just handbags closed cell foam is an excellent candidate for either. Foam is used within purses and wallets to add shape to the outer casing, travel luggage for form and structure, laptop and camera cases for protection and nappy bags for shape, safety and thermal insulation of some of the anticipated contents.

We can split, saw, rout, die cut, water-jet cut, butt-weld, laminate, adhere, thermoform or compression mould and cut to size all of our foams, to create even the most complex shapes and sizes. We can supply our polyethylene foam in sheets, rolls and blocks.

Whatever you’d like to achieve, our expert team can work with you to design and develop products and components, choosing and using the very best materials for the job. Talk to us about your latest challenge today.

Retail outlets and manufacturers exhibiting in the Homeware and Hospitality sectors are always looking for new ways to delight customers. Closed cell foam can be manufactured and shaped to produce immaculate displays to create uniformity and aspirational presentations for any customer requirements. Whether that’s for towel displays, drapes or bed linen, our closed cell foam blocks can be used for horizontal and vertical displays.

Using a cross-linked closed cell polyethylene foam for towel displays allows for the perfect shape and size to be created in orderly blocks. Fabric is laid and tucked against the rounded, smooth bends of the foam and is easily kept in place by each crease.

It’s incredibly simple to create impeccably neat displays for windows, stores and exhibition stands and doesn’t require any staff training. Only one towel is needed to create the effect and saves heavily on using product for the purpose of display.

They can be used as free standing blocks and do not require any attachments to be fixed to walls or table tops.

Several of the benefits for using closed cell polyethylene foam for displays are:

• It’s lightweight & Cost effective
• The foam can be made into any shape
• Strong and tear resistant
• Non Toxic
• Waterproof & Chemical resistant
• More durable than some foams
• Easily joined together with a glue gun or heat, if required
• It’s antibacterial

Using foam display blocks shows the product in its best light and it’s formulaic and aesthetically pleasing consistency, sparks the desire in customers to have the same product in their home or hotel.

Zouch have been supplying foam solutions for over 20 years and have a wealth of knowledge and experience when it comes to creating point of display solutions. We can work with you from inception to end solution to create the perfect shape, size and density for your display.

Whatever you’d like to achieve, our expert team can work with you on the design and development of your project, as well as suggesting the very best materials for the job.

As well as die cutting we can split, saw, rout, water-jet cut, butt-weld, laminate, adhere, thermoform or compression mould all of our foams to create even the most complex shapes and sizes.

Speak to us about your latest challenge and we’ll take an unbiased view to help you achieve the very best outcome for your product packaging.

In recent years, Britons have become well known for being the “Staycation Nation” as UK holiday destinations grow more popular with families opting out of stays abroad.

With Cornwall coming out on top as the UK destination and Devon as a close second, rural breaks alongside the breathtaking UK landscape are the go-to havens for holidaymakers. That, in turn, has had a positive effect on the demand for more comfortable and luxurious accommodation.

With families spending several weeks over the summer away - they’re seeking a home from home - and caravans and motorhomes are more often the favoured type of accommodation for households.

Many holiday parks with static caravans, single axle caravans and motorhomes have overhauled the interior of the trailers to improve all around amenity, comfort, and enjoyment for a holidaymakers stay. The most popular cushioning used is closed cell polyethylene foam (PE foam) as its varying benefits make it an excellent candidate for furnishings.

Durable

Closed cell polyethylene foam is incredibly durable with regular use, which is advantageous for holiday parks with weekly visitors throughout seasons. Due to its closed cell properties and formation, it doesn’t crumble or break like some foams, and retains its form with use. It also absorbs impact incredibly well for playful children and animals.

Lightweight

Many interior cabins require cushioning that is easy to move and store - whether that’s for movability when cleaning or for access to sofa beds built into lounge areas, closed cell foam won’t be a strain to lift.

Comfortable

Closed cell foam comes in sheets as well as blocks and can be customised to a required shape. Its closed cell formation give it a sturdiness that it both comfortable and supportive for the sitter.

Resistance

Water resistant, chemical resistant and flame retardant, closed cell foam also come in antibacterial grades to keep the foam clean with regular use and maintain low odour.

Lower cost alternative

Despite closed cell PE foams many benefits and high performance, it is still a low cost alternative and makes for an excellent option for a robust foam that needs to be routinely changed.

Our closed cell foam is available in a range of grades and densities, as well as sheets, rolls and blocks. Whatever you’d like to achieve, our expert team can work with you to design and develop suitable cushioning whilst using the very best materials for the job.

We can split, saw, rout, die cut, water-jet cut, butt-weld, laminate, adhere, thermoform or compression mould all of our foams to create even the most complex shapes and sizes, so talk to us about your latest challenge. Get in touch with you project and speak to one of our experts.

Polyurethane (PU) is a low density polymer that is widely used throughout the automotive industry for vehicle manufacturing applications. Most polyurethanes are thermosetting polymers and that means they do not melt when heated, which is especially important for vehicle and passenger safety.

Rigid PU foams are one of the most popular polymers for energy efficiencies and act as a very versatile form of insulation, for both heat and sound, within a vehicle’s interior cabin. Due to PU foams effectiveness, it dramatically cuts down costs when maintaining temperatures and decreasing the noise levels of exterior car sounds.

However, although the main areas for noise originates from the engine, suspension and tires, maintaining in-car noise has become just as important to car manufacturers, since the production of handsfree communication and GPS. The interior acoustics need as much consideration as the exterior, and so, PU foams ability to reduce sound by absorbing noise and vibrations is a big benefit to vehicle design.

Noise reduction is essential to passenger safety, as loss of concentration has a negative impact on driving behaviour and causes longer reaction times, inadequate observation and hazardous braking.

Polyurethane is versatile and can easily be adapted for freedom of design, as well as being greatly affordable. It’s a great alternative for keeping costs lower for both the manufacturer and the consumer, as due to its lightweight qualities, it also benefits the consumer when considering the increase in fuel costs.

PU Foam is often used within homes due to its superior insulative qualities and is known for its ability to maintain and control temperature, whilst managing energy efficiently. Polyurethane has one of the highest thermal resistances despite its low density too.

Key benefits of polyurethane foam:

• Lightweight and flexible
• Sound and vibration dampening
• High performing thermal insulator

At Zouch, our specialist automotive and transportation foams are lightweight, flexible and capable of performing to exceptional levels, in even the most demanding conditions. Our in-house design and development engineers are constantly focused on optimum comfort and cost effectiveness, as well as on reducing environmental impact and vehicle weight.

Which is why you’ll find our smart, state-of-the-art products in the interiors, exteriors and engine compartments of thousands of cars, buses, trucks, excavators and recreational vehicles worldwide. Get in touch with our expert team to discuss your specific application and we will support you from prototype to road-ready product.

During these unprecedented times, we’re working with the NHS to manufacture PPE medical grade face visors for infection control, to protect the frontline healthcare workers tirelessly combatting the outbreak.

Face shields protect the wearer's facial area against particles associated with COVID-19, preventing splashes and splatters of body fluids from coming into contact with the wearer’s eyes, nose and mouth.

They’re an absolutely essential element of PPE (Personal Protective Equipment) for healthcare workers to use whilst testing and caring for patients with Coronavirus, as the face has been reported to be the body part most commonly contaminated during procedures. Medical grade face shields are made up of Latex Free elastic, perspex or PVC and a ultra soft foam cushioning aid, to cover the face from the hairline and over the chin for full protection.

Our UK based manufacturers and warehouses are able to produce medical grade face shields daily, and are already gearing up to begin production for NHS Birmingham and Lincoln as of April 2020 - to help meet the ever growing demand for face visors for healthcare workers across the UK.

Our medical grade open cell polyurethane foam can be die cut or converted into any size or shape that is needed, as part of the face visors components, to add comfort to the wearer so the plastic shield isn’t directly in contact with the forehead.

Benefits of medical grade open cell polyurethane foam

Soft and comfortable

Open cell polyurethane foam is often used for products such as baby sponges and make up sponges, as it’s both kind to the skin and soft to the touch: meaning that it’s especially comfortable to the wearer. It conforms exceptionally well to body surfaces, providing flexible cushioning that doesn’t irritate delicate skin.

Medical grade

In the healthcare market, our foams are providing healthcare professionals with more advanced, effective products. Our medical grade foams are hypoallergenic, skin friendly and designed for medical or surgical use.

Non-toxic

All of our foams are designed and manufactured to be non-toxic and our medical grade open cell polyurethane foam has been exclusively designed for contact with the skin.

If you’re a medical supplier looking for face shields and visors during the Coronavirus outbreak, we can help and are with you every step of the way. Simply get in touch via our online form, email us at sales@zouchconverters.co.uk or call us on +44 (0) 115 856 2025.

We recently worked with Safer Equine, who have revolutionised Equestrian jump training through a new innovative jump system, which has used Zouch Converters’ closed cell foam for the system’s jump wings.

Safer Equine has been developed by Dr Emma Punt who has worked as an Equine and Canine McTimoney chiropractor for over 15 years.

I have treated many horses that have been injured whilst jumping and was interested in developing a safer jump wing. The Safer Equine Jump Wing has revolutionised jump training with this innovative jump system. They are lightweight, portable and manoeuvrable and have already been acclaimed by top trainers as the benchmark for modern jump training.

- Dr Emma Punt, McTimoney Equine and Canine Therapist

The unique shape, colour and design of the closed cell foam Safer Equine Jump Wing introduces variety into the training arena, to both challenge and train horses to listen to the rider and understand the jumping question.

Zouch Converters’ high-performance polyethylene foam has been created with aviation-spec in mind. The cross-linked closed cell foam is incredibly lightweight making the jump wings very easy to transport and be used anytime, anywhere.

They’re perfect for all riders, trainers and instructors, and are particularly great for jump clinics. The closed cell foam is also extremely durable with its high strength-to-weight-ratio, meaning that it will endure continuous training.

Our closed cell efoam is available in a variety of colour options, meaning Safer Equine and their customers are not restricted by shade, as well as being water resistant, washable and frost resistance. We can also offer personalisation by laser etching and engraving initials or letters into the foam.

We are delighted to have been involved with Emma in the design and development of this ground-breaking jump system. At Zouch we are always proud to be associated with products which improve health and safety and these jump wings are certainly doing so for both horses and riders.

- Rob West, Owner, Zouch Converters

If you’re interested in speaking to Zouch Converters about your next challenge, get in touch with our expert team and we’ll work with you to design and develop your idea to make it a reality.

After consulting with our client and her ideas we supplied her with Zouch eFoam XLPE 40, a closed cell polyethylene foam. The foam was placed in the water to which the sculptures were attached. Allowing the swan sculptures to float and how amazing they look.
 
Zouch Converters only played a small part in supplying the foam. The rest is down to the talent of Lyndall.

View Article here: https://www.zouchconverters.co.uk/case-studies/making-the-swans-float

Credits
Lyndall Phelps – Adopt a Sculpture
Photography by Richard Davis
Commissioned by Peterborough Presents

We have always associated the glorious intoxicating warm and languorous days of summer with getting gorgeous.

After a long period of hibernation its time to see everyone getting those”beach ready” treatments done. From pedicures to waxing and not forgetting those eyelash extensions. It’s a busy time for the beauty industry.

Zouch Converters presence within the beauty industry has been projected by the wide and varied products that we have designed and manufactured for a rapidly expanding award winning global brand.

Two years ago we were approached by this company who were at the time buying products from the Middle East. The skin contact adhesive on these products were causing skin irritations and issues with the product itself and the effectiveness when used in their treatments. Enter Zouch Converters!

After meeting and consulting with the company we not only solved the problem they had with the skin friendly adhesives but they have since extended the range of new bespoke made products we now supply in to them.

They are happy to be working with us and to have moved their business back to a UK supplier.

Zouch Converters offer environmentally friendly, hypo-allergenic, quality foam products to suit all sectors of the cosmetic market.

We were approached last year by a small creative team specialising in personalised gifts. They put their hearts and souls into their designs and everything they make is created with care. It was then up to us to keep it safe.

After the initial consultation, their idea was to present ten test tubes tucked up in a luxury white box. They needed us to provide them with a foam to keep the test tubes securely in place, as well as adding padding and protection to ensure that their product reached their customer in perfect condition during transit.

Zouch Converters do do a very nice job for us indeed, lovely to deal with too.

- The Happy Makehouse

Whilst The Happy Makehouse had the creative side covered, it was down to Zouch to provide the protection. Using our ZOUCH eFoam range which are a collection of robust, closed-cell polyethylene foams, we produced a foam strip with a self-adhesive backing on, with one side adhered to the box on either side to keep the test tubes nice and snug.

How good does it look? Simple but effective. We love watching The Happy Makehouse grow as a company and our partnership helps us all achieve incredible things.

- Rob West, Owner, Zouch Converters

Our extensive range of closed-cell polyethylene foams benefit from being chemically inert, lightweight and resistant to chemicals and water, and are low cost, making them an ideal high-performance packaging solution. Find out more about our innovative packaging and protection solutions or get in touch to talk through your project with one of our expert team members.

On the 27th November 2014 Cricketer Phillip Hughes tragically died after being struck in the neck by a bouncer during the match between South Australia and New South Wales two days prior.

The very next day major voices in the sport spoke of how this would have to lead to further improvement in the design of helmets including leading sporting brands and former professionals such as Nasser Hussain.

Soon after, a market leading, UK based helmet manufacturer approached a number of companies to present ideas on how neck protection could be incorporated into helmets while at the same time sacrificing as little comfort and performance as possible.

Having supported leading brands in the sporting sector for over a decade, Zouch Converters have developed an incredible reputation and we were honoured to be approached as one of the few to provide a concept. As big cricket fans ourselves, we felt we would be the perfect candidate to play an essential role in ensuring the safety of our future cricketers.

We immediately got to the drawing board and began developing ideas quickly turning into prototypes using our world class foams. After 2 years of intense testing at Loughborough University, our product was chosen as the finest, providing the perfect balance of safety and performance that was highlighted as a key attribute needed in the design of neck protection.
 
The chosen material is a unique synthetic closed cell rubber from our ZOUCHflex range, which is both durable and lightweight and has high impact cushioning in order to prevent trauma to the wearer whilst providing comfort and flexibility.

Now, in 2018 we find ourselves manufacturing our patented neck protectors for a world-renowned cricket brand and being sold alongside their helmets both online and on the high street by major sporting equipment distributors.

We feel incredibly proud in the knowledge that Zouch Converters will be keeping the current and next generation of cricketers safe.

We are excited to announce that our new website is now live. Helping bring major improvements for our customers, our new website is faster, easier to navigate and brings a wide range of new developments including:

• A new fully responsive design aimed to provide an optimal viewing and browsing experience across multiple platforms, including your smartphone for on the move browsing!
• A much more modern fresh interface, optimised fully for user navigation.
• A showcase of our products in their truest form, with descriptive information to help benefit each visitor.
• Our new updated Zouch logo and identity.
• Exciting project case studies.

We are proud to have partners with Colebridge Enterprises to provide employment and training services for learning disabled adults, young people and the long tern employed who suffer from mental health illness.

Five decades after it heralded a transformation in the way people obtained & used cash, the site of the worlds first cash machine was turned to gold to celebrate its 50th anniversary in June.

Since that very first launch there are now around 70,000 cash machines across the UK & 176 million cards in the UK that can be used to withdraw cash at them. 

Where would we be without them? Cash still remains a crucial part of our day-to-day lives – whether its to pay for groceries or doing the office coffee run in the mornings as we do here!

Zouch have had the pleasure over the last 6 years of working alongside NCR, who are one of the global leaders of ATMs and consumer transaction technology. Zouch manufacture and supply technical and precise components that are used within the NCR Corporation. Here we undertake strict manufacturing protocol which result in a precise performance part that excels in such a demanding application used continuously 24 hours a day, 7days a week and 364 days a year!

NCR aim to make the ATM a “bank branch in a box” saying that their research showed that 80% of the transactions completed within a typical banking branch could be completed through a video teller at an ATM in future.

Here’s to the next 50 years!