XLPE vs PE vs EPE Foam: Which One is Better?

When choosing a foam for your packaging application, we often get the question: Which one is the best?

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&#;Best&#; is subjective, of course, and it also depends on your specific application. However, there&#;s always an answer. Today, our team at Foam Industries will compare the three most popular types of foam used in packaging &#; XPLE, PE, and EPE &#; and answer the question: which one is the best choice.

What is XPLE Foam?

Cross&#;Linked Polyethylene (XLPE) Foam  is the marriage of unparalleled durability and unlimited aesthetics. It&#;s essentially a more magnified version of polyethylene foam (PE) and is specially made to be &#;cross-linked,&#; meaning that there&#;s extra-strength foam bonding that leads to high resistance, strength, and durability. Essentially, XLPE foam is the Hulk-ified version of regular polyethylene foam. XLPE is extremely durable and rigid to keep merchandise safe, yet doesn&#;t scratch painted surfaces. While it has a variety of applications, it&#;s extremely well-suited for influencer kits and other marketing materials where safe delivery, the unboxing experience, and display are all critical.

&#; Related Content: Benefits of Cross&#;Linked Polyethylene Foam in Packaging

What is PE Foam?

Polyethylene (PE) Foam is low cost, resilient to chemicals and water, and industrially recyclable. It&#;s suited for a wide variety of applications &#; end caps, case inserts, and other common types of packaging. By melting plastic and adding gas bubbles to the mixture, it results in a cushion-like foam that&#;s both soft and protective. 

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What is EPE Foam?

Expanded Polyethylene (EPE) Foam is ideal for applications where flexibility in design but rigidity in form is crucial. EPE foam starts as a bunch of plastic beads, becomes heated up, and is combined with air to form a lightweight foam. The air bubbles help the dense plastic to become lighter and create cushioning by forming a soft, sponge-like material. This can be used in various industries for packaging or creating goods.

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Comparing XLPE, PE and EPE Foam

With so many foam types, it can be overwhelming to determine what works best for your project, but we&#;re here to make it easier. Compare cost, performance, moisture resistance, strength, insulative, and environmental impact below for cross-linked polyethylene, polyethylene, and expanded polyethylene foam.

Quick Comparison

Performance

• XLPE Foam: Highest temperature resistance (up to 194°F continuously; 266°F for brief periods)
• PE Foam: Moderate temperature resistance (up to 176°F continuously)
• EPE Foam: Lower temperature resistance (up to 158°F continuously)

Moisture Resistance

• XLPE Foam: Highly water resistant
• PE Foam: Water and mold-resistant with closed-cell types
• EPE Foam: Water, chemical, and fungus resistant

Strength

• XLPE Foam: Extra strong and durable
• PE Foam: Decently strong and durable
• EPE Foam: Less strength and durability

Electrical Insulation

• XLPE Foam: Cross-linked structure provides better insulation
• PE Foam: Less effective than XLPE but more than EPE
• EPE Foam: Open-cell structure provides less insulation

Thermal Insulation

• XLPE Foam: Excellent insulation with closed-cell structure
• PE Foam: Offers better insulation than EPE but not as much as XLPE
• EPE Foam: Provides decent insulation but not it&#;s strong suit

Environmental Impact

• XLPE Foam: Less recyclable and uses more energy to manufacture
• PE Foam: Recyclable and uses less energy to manufacture
• EPE Foam: Recyclable and uses less energy to manufacture

Which Type of Foam is the Best for Packaging?

Which type of foam is the best for packaging? This is the question we get the most, and it&#;s the hardest to answer generally because it depends on what your product is, your budget, how it will be shipped, if it will be displayed after, etc. 

At Foam Industries, we love all foam &#; but there&#;s a correct foam to use for every given packaging scenario. Heavier or more fragile shipments are going to have the safest journey cushioned by XLPE foam while delicate or high-density shipments are going to want to snuggle up in EPE or PE foam. EPE or XLPE foam are best for insulating. PE is the cheapest while XLPE is the strongest. When deciding which foam to use, keep your product in mind.

However, for a vast majority of applications, our recommendation is usually Polyethylene (PE) Foam for a couple of reasons:

• It has decent durability, is water-resistant, and chemical-resistant. This makes it well-suited for protecting most products.
• It&#;s very low-cost compared to other foam options, which makes it an excellent choice for case inserts and other applications where a design will be re-used multiple times.
• It&#;s over 100% circular. This means that we can re-use every piece of PE foam to create a new application without losing performance. We also recycle other companies PE scrap as well.

&#; Related Content: How to Choose the Right Foam for Your Custom Case Insert

Find Your Best Option with a Packaging Expert

As a leader in the packaging industry, Foam Industries has set the bar with an unwavering commitment to quality, exceptional client service, and constant innovation. Through our extensive inventory of endlessly customizable products, we ensure you find exactly what you&#;re looking for.

Contact a Packaging Expert

Foam Industries is a custom protective packaging company specializing in foam &#; with additional wood and plastic fabrication services. Our custom foam fabrication services are ideal for any type of packaging, display, or support service needed &#; from design to finished product.

Contact us to discuss your requirements of Polyethylene Foam Foil(es,it,de). Our experienced sales team can help you identify the options that best suit your needs.