SCA Foam Products General Packaging and Components
Masterminding the vision Challenging convention Engineering the change
SCA Foam Products, part of the SCA Packaging Group, is a premier supplier of custom designed cushioning products, material handling and speciality components, serving the needs of many of the world’s largest manufacturing companies. SCA Packaging operates from over 300 locations, throughout the UK, Europe and Asia. Our combined knowledge and experience makes us an ideal packaging solutions supplier. With five strategically placed manufacturing sites in the UK, SCA Foam Products offers excellent geographical coverage to meet our customers’ requirements. Our commitment to investing in the most up to date design and manufacturing technology ensures the highest standard of product quality and efficient production capability within the industry.
Specially trained packaging design engineers located at the Northampton Technical Centre provide customers with powerful resources. Our proven design, engineering and technical problem solving expertise is recognised worldwide within the high tech, consumer electronics, major appliance and automotive markets. Packaging is no longer perceived as just packaging, it plays an important role in the perception of quality products. With state-of-the-art processing equipment, SCA Foam Products manufactures protective products using a variety of foam materials including expanded polystyrene, expanded polypropylene and all known copolymers. Our commitment is to serve the specific needs of our customers with simple cost effective packaging solutions.
Technical Centre Our capabilities and equipment at our technical centre located in Northampton are second to none. We are proud of our facilities but even more outstanding is our award winning technical design team. SCA Foam Products design team’s individual talents are drawn from their engineering and CAD design backgrounds. Their skills cover many disciplines; engineering, graphic design, tooling, pattern making and sampling coupled with an extensive knowledge of materials. These combined skills create a dynamic problem solving team whose innovative new concepts and ideas radically improve on a products’ packaging protection, whilst also satisfying client requirements to save cost and improve efficiency - logistical issues of delivery, assembly, storage and despatch are addressed as a matter of course.
The state of the art technical centre in Northampton
Add SCA Foam Products global collaboration to our
has the latest CAD design technology. Working with 7
designers’ expertise and you truly have a world of
networked Pro Engineer CAD stations the design team are
knowledge at your fingertips.
leading the way with innovative packaging solutions. High quality precision prototypes are produced directly from CAD data using the latest technology in CNC machinery. Our computer controlled machines have multi tool change capabilities to speed sample production and efficiency. These powerful machines cut low to high densities of expanded foam to produce accurate samples for fit and evaluation. Hot wire cutting is also used where the dimensional tolerances are not super critical. SCA Foam Products has the capability to simulate transit conditions and evaluate physical and mechanical handling in the distribution environment to determine the effectiveness of the cushioning, durability and other critical design attributes of the pack. All testing is done in house therefore data is available immediately.
Testing Facilities Multiple Type Drop Testing The “heavyweight” drop tester accommodates large products such as home appliances, televisions and computer equipment ensuring simulation of true freefall drops. Transient
Lightweight Drop Tester
acceleration signals are displayed on the system monitor and the computer analyses the results. The “lightweight” model tests smaller lighter packages that are generally handled manually.
‘Real Life’ Handling Test Warehouse damage is dramatically reduced by our ability to recommend the correct materials and density
Heavyweight Drop Tester
suitable for clamp truck and manual handling. Using a calibrated clamp truck for ‘real life’ trials we measure pressure/deflection - vital information required to design protection for the vulnerable sides of large products.
Transport Simulator Our transport simulator imitates the movement and vibration a product would be subjected to whilst being transported on a vehicle. This covers all road conditions and journey lengths. The pack moves freely on the simulator and all faces of the package are tested, facilitating an accurate test for mixed loads.
Inclined Plane The inclined plane simulates sudden arrest - such as a rail car shunting or a vehicle stopping rapidly. A test often required for the white goods industry and where products are stacked together on a pallet.
The individual talents and collective experience of SCA Foam Products design team, backed by state of the art testing facilities, always leads to exciting new packaging solutions.
Inclined Plane
Engineered Foam Solutions SCA Foam Products extensive knowledge and material neutral approach ensures we offer the best optimum engineered solution to meet your packaging requirements. Our foam moulding facilities have state-of-the-art processing equipment to manufacture products to meet customer specifications and to address the requirements of a multitude of industries. The expanded foam materials we use include polystyrene (EPS), polypropylene (EPP), SupraCell™, Arcel and Hi-Heat resins. These foams have specific characteristics, which suit different application areas (please refer to Materials Matrix).
The versatility of expanded foam lends itself to be
packaging, where the expanded foam plays a vital part in
easily branded. Simply adding a plate within the
the aesthetic appeal of the product.
tool can personalise your product by creating logos, numbers and lettering or instructions, for example for
Colour can also add appeal to the packaging. A variety
packing/unpacking directives. Recycling awareness
of coloured foams are available, from soft pastels to
can also be highlighted.
intense colour. Colour is ideal for product identification, differentiation, or just to suit a company’s corporate colour
The plate can be easily interchanged for different information requirements or to update information changes. Trade or product names are often included within customers’ expanded foam mouldings to enhance awareness of the company image or quality of the product. Moulded foam parts can be more than just packaging; it can very much form part of the final product. The standard flat surface of the tooling may be produced ‘etched’ to create a textured finish or pattern, such as leather or grained effects. These options are usually chosen for automotive applications or for display
identity.
Fabricated Foam Solutions SCA Foam Products can also supply fabricated foam solutions, as well as moulded foams. We are converters of non-cross linked polyethylene foam, cross-linked polyethylene foam and polyurethane foam and can supply these materials produced using a variety of techniques.
With a global network of major suppliers, SCA Foam Products can recommend and supply the materials best
Materials can be die cut, heat welded and assembled.
suited to providing optimum product protection. Our
We can also supply thermoformed, routed and water
extensive range of materials enables us to supply products
jet cut parts.
to meet most manufacturing specifications and to address the requirements of a multitude of industries. We can even
Fabricated foam solutions offer excellent cushioning
assemble and deliver your customised packaging line-side
and are ideal for smaller production runs, or where
in a ready to use form.
product launches have a very short time span. The tooling is less complex than for moulded foams and
Whatever your protective packaging requirements, you
can be in place within days, as opposed to weeks. The
can rely on the expert in-house team at SCA Foam
range of stock materials we hold enables us to offer a
Products to provide a practical, cost effective high quality
fast delivery service.
solution.
SupraTec SCA Foam Products has developed insert moulding
An additional five fixing components are moulded into
to another dimension. Using advanced manufacturing
the Air Minder body casing.
techniques (SupraTec); we can process ABS casings by moulding in expanded polystyrene to become airtight whilst allowing multiple materials to also be included, such as fixing components. Working in partnership with Vent-Axia Ltd, the SupraTec process was applied to produce the award winning ‘Air Minder’ domestic heat recovery system. The Air Minder unit consists of a two part outer casing with four turrets that are lined with polystyrene. Attention to shrinkage and tolerance has to be paramount to ensure the outer casing and expanded foam are sealed airtight together. Channels are moulded into the polystyrene to fix and retain the internal components and provide cable routing.
Four ducting turrets are lined with expanded polystyrene using a unique three-dimensional moulding technique, which is the first ever process achievement of this kind.
SupraCell™ SupraCell™ is a reusable packaging system stronger than EPS, cheaper than EPE, EPP and Arcel and offers improved packaging performance. Researched and developed over a 10-year period in response to our customers’ demand for a material with similar high quality properties to foams produced in Asia, SCA Foam Products SupraCell™ now fills the void. SupraCell™ is a styrenic material process that affords better product protection than expanded polystyrene (EPS). It has proven to have 25% better cushioning, with high fusion levels and improved tensile strength and outperforms EPS in multi drop tests.
SupraCell™ is a lightweight, fully recyclable, robust styrenic that compares to the properties of EPP, EPE and Arcel, but at a more competitive cost. Full transit tests have been carried out in house at SCA Foam Products technical centre and in independent trials by PIRA, SupraCell™ lived up to the expected improvements in performance criteria. SCA Foam Products manufactures SupraCell™ using a process far more complex than the industry standard for expanded polystyrene or polyolefin materials and is only available from SCA Foam Products. Originally created for the electronics industry, SupraCell™ material has developed to become the perfect low cost option for reusable packaging systems. Ultra low densities are also available to replace EPS for one trip packaging of very fragile goods.
SupraSkin™ SupraSkin™ is a moulding process which is used to give an expanded foam body (EPP, EPS and all CoPolymers) a skinned surface which offers increased tensile and compressive strength. It also can be used as a protective layer and can be enhanced aesthetically by the use of colour and surface finishes. In comparison with skinning processes which bring two individual products with varying tolerances together, SupraSkin™ is produced in one complete process and therefore saves manufacturing costs. The other most common process is where a solid sheet plastic skin is introduced into the EPS mould at the end of the cycle to fuse the two products together. However, due to the fact that steam cannot pass through a solid, the mechanical bond is weak and produces no performance enhancements. The SupraSkin™ process is very similar EXCEPT that the membrane
is porous and therefore facilitates the passage of steam, resulting in the expanded foam bead and the surface skin completely fusing together to become one component. SupraSkin™ provides extra strength, improving impact protection as well as scuffing resistance. It has many applications in components where it can be used to replace injection moulded outer parts as well as improving the impact performance of the total unit.
EPS Sample
SupraSkin™ Sample
The technical benefits of SupraSkin™ include:
Improved impact protection
Added strength
Abrasion & scuffing resistance
Adds a protective covering
Moisture resistant
May be used to ‘hinge’ products
Various colours available
The SupraSkin™ process can be applied in various thicknesses and because it ‘melts’ with the EPS, there is no loss of definition. Detail such as lettering and recycling symbols etc. are still clearly visible.
Insert Moulding Our expanded foam moulding expertise encompasses many diverse manufacturing processes, one of which is insert moulding. In lower densities it is flexible enough to grip other components into place or even moulded around other materials, such as plastic, metal fixings units and wood, making them an integral part of the component. This is an ideal application where expanded foam components require fixing into place, forming part of the final product. A double transfer press automatically moulds in the additional parts. For example, an air conditioning pan unit is created by moulding expanded foam around a vacuum forming and a second stage moulds in plastic plugs and metal fixings, resulting in a lightweight, waterproof component ready to place. The options are endless and remember expanded foam is lightweight, insulating, sound deadening, protective and of course, fully recyclable.
Engineered Components The versatility and the energy management property of expanded foam lend itself to much more than just packaging. It may be moulded into shape to become a key part of the final product. For example, children’s car seats, water cooler insulation jackets and vacuum cleaner motor housing. Expanded foam is an ideal material for reducing noise and vibration and may even reduce the level of the outer packaging requirement. When expanded polypropylene is produced at high densities (eg 200g/l) it becomes rigid and has a high strength to weight ratio. Tooling costs can be as low as 10% of the price of injection moulding tools (£10,000 compared to £100,000) and has a much shorter lead-time. SCA Foam Products work with Pro Engineer solid modelling linked to CNC routers for accuracy and efficiency of producing samples.
PolyPallet™ The Returnable Pallet Box System In response to the demise in acceptability of wooden
lid locks firmly over the top to complete the flat pack.
pallets in certain markets, SCA Foam Products
Reducing the volume obviously creates major transport
Research & Development team has evolved a
cost savings.
returnable pallet box system, which packs flat for the return journey.
The PolyPallet™ Box system has been independently tested at Pira International (ISO 8611:1991) to ensure
The PolyPallet™ Box consists of a base pallet
suitability of the pallet combination for storage in
moulded in Arcel material and AC flute heavy grade
warehouse racking systems as well as in general
corrugated sidewalls topped with an A flute grade
stacking conditions.
lid. The sidewalls are held firmly to the Arcel base by a unique ‘stirrup lock’. Arcel is a very hardwearing, lightweight material that may be custom manufactured to suit customer’s individual product requirements. For the return journey, the sleeve collapses down to fit within the outer perimeter of the pallet and the
Why Choose PolyPallet™?
Beam rackable (250kg - Report Pira Int.)
Stackable
Competitive pricing
Returnable / Reusable
4 way entry
Clean and contamination free
Timber free
Branding - Sleeve may be personalised
with special markings
100% Recyclable
PolyPallet™ Expanded Foam Pallet If you are looking for a hygienic alternative to conventional wooden pallets, then look no further. SCA Foam Products has the answer .... the PolyPallet™. This expanded foam pallet is timber free, eliminating the need to meet the export requirements for wooden packaging materials of heat treatment or fumigation (ISPM 15). Splinter, nail and dust free, PolyPallet™ is easier to handle than wooden pallets and they are so lightweight shipping costs may be reduced.
PolyPallet™ is available in two standard sizes, 1200 x 1000 and Euro size 1200 x 800 but may also be custom designed to meet your requirements. The pallet surface may be adapted to customer’s own specifications. Or why not consider coloured pallets for easier product identification or branding. End of life disposal is simple, as expanded foam is fully recyclable.
Timber Free
Hygienic - Ideal for food and
pharmaceutical usage
Lightweight Durable
Splinter, nail & dust free
Pest free
Shock pallet potential
100% recyclable
Material Selection Matrix Family of Foams-Performance Characteristics and Application Areas
Product
EPP Resins
SupraCell™
Expanded Polypropylene
Regular: balance of flexibility and strength
Performance Features
Light: high energy absorption. Excellent cushioning
Regular: Reusable packaging bulk pack trays
Application Areas
Light: Protective packaging of highly fragile products
SupraCell™ Regular SupraCell™ Light
Trade Names*
Compressive Creep Resistance Comparison
EPS Resins Expanded Polystyrene
ARCEL® Resins
Hi Heat Resins
Polyethylene/Polystyrene Copolymers
Expanded Copolymers
High energy absorption Excellent cushioning over broad loading range High service temperature
Good strength Good first drop cushioning performance Excellent insulation value
A balance of flexibility and strength Tough-puncture resistant Very good solvent resistance
High Strength characteristics Mouldable in very high densities, up to 10pcf/ 160.2kg/m³ High service temperature, up to 250° F/121°C
Protective packaging of high-value, highly fragile electronics Heat resistant packaging Energy-absorbing automotive-bumpers and components
Packaging for consumer electronics appliances, toys Food service cups, coolers Insulation-roof insulation, sheathing board
Reusable packaging and packaging of heavyweight items Bulk pack trays and tote bins Water sports equipment
Lightweight automotive interior components Building panels and solar panels Cabinetry
ARPRO® EPERAN PP® NEOPOLEN P®
STYROPOR® NOVA RIGIPORE®
ARCEL®
NORYL® GECET™
Resiliency Comparison
Service Temperature Comparison
Compressive Strength Comparison
Chemical Resistance Comparison to Gasoline-Type Solvents Excellent
Good
Fair
Poor
EPE
EPP
ARCEL
EPS
Hi Heat Resins
EPS & Hi Heat Resins
ARCEL
EPP
EPE
EPS
ARCEL & EPE
EPP
Hi Heat Resins
EPE
EPP
ARCEL
EPS
Hi Heat Resins
EPS & Hi Heat Resins
ARCEL
EPP
EPE
Typical Physical Properties of Moulded Foams Properties ASTM Test
Typical Density Range
Density of Foam Tested
Compressive Strength Tensile Strength (at 25% compression) (at break)
pcf
Kgs/m³
pcf
Kgs/m³
psi
kPa
psi
-
-
-
-
D3575
Light Regular
12-14 18-22
14.0 22.0
UTP UTP
UTP UTP
UTP UTP
Tensile Tear Elongation Strength
Kgs/cm²
%
lbs./in.
D3575
D3575
UTP UTP
UTP UTP
UTP UTP
D3575
Dynamic Set
Kgs/cm
Compressive Creep (% of after 1,000 hours)
%
4 psi
D1596
D3575
UTP UTP
UTP UTP
UTP UTP
.28 Kgs/cm²
Service Temperature
˚F
˚C
ARCO
Thermal Resistance Per inch
2.54 cm (R) C518
Products SupraCell™
UTP UTP
175
79
3.9
190 210
88 99
3.6 3.7
EPP Resins
1.0-5.0 16.2-80.1 1.0-5.0 16.2-80.1
1.3 1.9
20.8 30.4
10 16
69.0 110.3
35 52
2.5 3.7
18 22
7.0 9.0
1.2 1.6
1.1 1.0
EPS Resins
0.8-5.0 12.8-80.1
1.25
20.0
21
144.8
45
3.2
