Mailong Packaging recently supplied 27KG/m³ EPE foam sheets to a customer in Sydney, New South Wales, Australia, for product protection and customized protective packaging. The project required white expanded polyethylene foam sheets with a consistent density of 27 kg/m³, a standard working size of 1000 × 1000 mm, and two different thicknesses to accommodate different packaging requirements.
The final order consisted of 1,000 pieces of 20 mm EPE foam sheets and 1,000 pieces of 30 mm EPE foam sheets, for a total quantity of 2,000 pieces. The large-format sheets give the customer flexibility to cut the foam into protective pads, separators, inserts, edge protectors and other customized shapes.
Project Overview
- Customer: Australian customer
- Location: Sydney, New South Wales, Australia 2190
- Product: 27KG EPE Foam Sheets
- Material: EPE / Expanded Polyethylene Foam
- Density: 27 kg/m³
- Color: White
- Sheet Size: 1000 × 1000 mm
- Thickness: 20 mm and 30 mm
- Quantity: 1,000 pcs of each thickness
- Total Order: 2,000 pcs
- Main Application: Product protection and custom protective packaging
Australian Customer Requirement
The customer was looking for a reliable source of EPE foam sheets that could be used as a flexible protective material during product packaging, handling, storage and transportation.
Instead of using only finished packaging inserts, the customer preferred larger EPE foam sheets that could be cut into different sizes and shapes according to individual products. This approach provides greater flexibility when one packaging program involves multiple product dimensions.
The customer specifically requested a 27 kg/m³ EPE foam density with white color and a 1000 × 1000 mm sheet format. Two thickness specifications were required:
| Specification | Requirement |
|---|---|
| Material | Expanded Polyethylene (EPE) Foam |
| Density | 27 kg/m³ |
| Color | White |
| Sheet Size | 1000 × 1000 mm |
| Thickness | 20 mm / 30 mm |
| 20 mm Quantity | 1,000 pcs |
| 30 mm Quantity | 1,000 pcs |
| Total Quantity | 2,000 pcs |
Why the Customer Selected 27KG EPE Foam
EPE foam is widely used for protective packaging because it combines a lightweight structure with cushioning, flexibility and easy processing. The material can be supplied in sheets or rolls and can subsequently be converted into packaging components based on product geometry.
For this project, the customer selected 27 kg/m³ density EPE foam as the required material specification. The 20 mm and 30 mm thickness options provided flexibility for applications requiring different amounts of protective material.
For businesses evaluating different grades of EPE, our EPE FOAM product category provides a broader overview of available EPE packaging materials and customization options.
Customized 27KG EPE Foam Sheet Solution
Mailong Packaging manufactured the foam sheets according to the customer’s specified density, dimensions, color and thickness requirements.
The final production was divided into two product specifications while maintaining the same material density and sheet dimensions.
| Product | Density | Size | Thickness | Quantity |
|---|---|---|---|---|
| White EPE Foam Sheet | 27 kg/m³ | 1000 × 1000 mm | 20 mm | 1,000 pcs |
| White EPE Foam Sheet | 27 kg/m³ | 1000 × 1000 mm | 30 mm | 1,000 pcs |
Customers looking for more detailed product information can review our EPE Foam Sheets product page, which covers sheet and roll formats for protective packaging applications.
How the EPE Foam Sheets Are Used
The primary purpose of the Australian project was to protect products from direct contact, surface friction and movement during packaging and transportation. Because the material was supplied as large 1000 × 1000 mm sheets, the customer can convert the foam into different protective components according to product requirements.
Protective Pads
The EPE sheets can be cut into flat pads and placed between products and cartons, crates or other packaging surfaces. These pads create a cushioning layer around the packaged product and help reduce direct contact during handling.
Custom Foam Inserts
For products requiring more precise positioning, the EPE material can be cut into customized inserts. The insert shape can be designed around the dimensions and geometry of the product to provide a more controlled packaging structure.
Edge and Corner Protection
Large EPE sheets can be converted into strips, blocks and shaped components for protecting vulnerable product edges and corners. This is particularly useful for products with irregular dimensions or protruding sections.
Interlayer Separators
EPE foam sheets can also be cut into separators between multiple products. This helps create physical spacing between items and reduces direct product-to-product contact during storage and transportation.
Special-Shaped Protective Components
One of the major advantages of purchasing EPE foam sheets from a manufacturer is the ability to further process the material. The customer can use the sheets to produce protective components with different dimensions and shapes rather than relying entirely on standard packaging sizes.
For additional ideas, see our detailed guide to EPE Foam Applications to explore how EPE foam can be used across modern packaging and industrial applications.
Available EPE Foam Sheet Specifications
Although this Australian project used 27KG/m³ white EPE foam, Mailong Packaging can provide a broader range of EPE densities, thicknesses, colors and dimensions for customized packaging projects.
| Parameter | Available Options |
|---|---|
| Material | EPE / Expanded Polyethylene Foam |
| Density | 18–100 kg/m³ or customized |
| Thickness | 5, 10, 15, 20, 25, 30, 40, 50, 60, 100 mm or customized |
| Color | White or Black |
| Sheet Size | Custom sizes available |
| Cutting | Any required size and customized shapes |
| Application | Product protection, cushioning, separation and protective packaging |
| MOQ | 100 pcs |
For customers comparing different EPE material formats, the dedicated EPE Foam product page provides additional information about EPE foam solutions and customization.
Custom EPE Foam Cutting for Different Products
Standard rectangular packaging is not always sufficient for products with irregular shapes. A major requirement in many B2B packaging projects is the ability to create protective components that match the product’s actual dimensions.
Mailong Packaging supports custom EPE foam cutting for customers that need specific dimensions or specially shaped protective components. Depending on the packaging design, EPE foam sheets can be converted into:
- Flat protective pads
- Custom foam inserts
- Product separators
- Edge protection strips
- Corner protection components
- Protective blocks
- Custom-shaped cushioning pieces
- Product-specific packaging components
This flexibility allows customers to purchase larger sheets and manufacture multiple protective components from the same basic material specification.
Why Large 1000 × 1000 mm EPE Sheets Are Practical for B2B Packaging
The 1000 × 1000 mm EPE foam sheet format provides a practical working surface for manufacturers, distributors and packaging companies that require flexible material conversion.
Rather than stocking a large number of different pre-cut protective parts, businesses can use larger EPE sheets and cut them according to their actual packaging requirements. This can be particularly useful when a company handles products with multiple dimensions.
The same 27KG/m³ EPE foam specification can therefore support different packaging configurations by changing the cutting dimensions and thickness selection.
EPE Foam Compared with Other Protective Packaging Materials
EPE foam is one of several materials used for protective packaging. The most suitable material depends on product weight, shape, surface sensitivity, packaging design and transportation requirements.
| Material | Typical Strength | Processing Flexibility | Common Packaging Role |
|---|---|---|---|
| EPE Foam | Lightweight cushioning and separation | Easy to cut and customize | Sheets, pads, inserts and protective components |
| EVA Foam | More structured foam solution | Excellent for custom fabrication | Inserts, liners and shaped components |
| Air Column Packaging | Inflatable cushioning | Inflatable packaging format | Individual product cushioning |
| Bubble Packaging | Flexible cushioning | Easy to wrap and cut | Surface wrapping and void protection |
For customers that need inflatable alternatives, Mailong Packaging also provides Air Column Bag solutions for products requiring inflatable protective packaging.
Our Bubble Cushioning Packaging is another option for applications where flexible bubble cushioning is preferred.
Packaging Quality and Manufacturing Control
For international B2B packaging projects, material consistency is just as important as the initial product specification. Density, thickness, dimensions and appearance all need to remain within the agreed production requirements.
Mailong Packaging follows a manufacturing and quality-control process designed to support stable production for international customers. Customers interested in our broader approach can read Packaging Quality Control to learn more about our quality processes.
For customers comparing protective packaging materials, our guide to Types of Bubble Wrap also provides useful background on different cushioning material formats.
Why Choose Mailong Packaging for Custom EPE Foam?
Established in 2009, Mailong Packaging is a professional manufacturer and exporter specializing in protective packaging materials for global industries.
Our product portfolio includes Inflatable Bubble and Pillow Film, Air Column Rolls, Air Column Bags, EPE & EVA Foam, Poly Mailers, Stretch Wrap, Bubble Mailers, BOPP Tape and Corrugated Boxes.
With more than 15 years of packaging manufacturing experience, we work with international customers that require stable quality, competitive pricing, flexible order quantities and customized packaging specifications.
| Mailong Packaging Advantage | Description |
|---|---|
| Industry Experience | More than 15 years of protective packaging manufacturing experience |
| Fast Production | Production completed within 3–7 days for suitable orders |
| Flexible MOQ | MOQ starting from 100 pieces |
| OEM & Customization | Custom sizes, materials, thicknesses, colors and designs available |
| Global Export Service | Products exported to more than 30 overseas markets |
Project Result: 2,000 Custom EPE Foam Sheets for Australia
The Australian customer received a total of 2,000 pieces of white 27KG/m³ EPE foam sheets in the requested 1000 × 1000 mm format.
| Item | Project Result |
|---|---|
| Density | 27 kg/m³ |
| Color | White |
| Sheet Size | 1000 × 1000 mm |
| 20 mm Sheets | 1,000 pcs |
| 30 mm Sheets | 1,000 pcs |
| Total | 2,000 pcs |
| Destination | Sydney, New South Wales, Australia |
| Primary Application | Product protection and custom protective packaging |
The project demonstrates how a standardized EPE foam sheet specification can be adapted to different packaging requirements through changes in thickness and cutting dimensions. Instead of purchasing only finished packaging components, the customer can use large-format EPE sheets as a flexible raw material for creating customized protection.
Custom EPE Foam Manufacturer for International Packaging Projects
Mailong Packaging supplies EPE foam materials to customers that require more than standard off-the-shelf packaging. From density and thickness selection to sheet dimensions and custom cutting, our goal is to provide a practical material solution around the customer’s actual product protection requirements.
Our EPE foam products are suitable for manufacturers, packaging distributors, logistics companies and other B2B customers looking for custom EPE foam sheets, EPE foam rolls, protective foam inserts and product-specific foam packaging.
For environmentally focused packaging programs, customers can also explore our Compostable Bubble Wrap as an alternative protective packaging material.
Frequently Asked Questions
What density EPE foam was used for this Australian project?
The customer selected 27 kg/m³ EPE foam in white color for this project.
What were the dimensions of the EPE foam sheets?
The sheets were supplied in a 1000 × 1000 mm format, with thicknesses of 20 mm and 30 mm.
How many EPE foam sheets were ordered?
The total order was 2,000 pieces, consisting of 1,000 pieces at 20 mm thickness and 1,000 pieces at 30 mm thickness.
Can EPE foam sheets be custom cut?
Yes. Mailong Packaging supports custom cutting according to required dimensions and protective packaging designs. EPE sheets can be converted into pads, inserts, separators, strips, blocks and other custom-shaped protective components.
What EPE foam densities are available?
Mailong Packaging can supply EPE foam in a density range of approximately 18–100 kg/m³, with customized specifications available according to project requirements.
What thicknesses are available for EPE foam sheets?
Common thicknesses include 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 40 mm, 50 mm, 60 mm and 100 mm. Custom thicknesses can also be discussed for specific projects.
Request Custom EPE Foam Sheets
If your business requires 27KG EPE foam sheets or another customized EPE foam specification, Mailong Packaging can provide a solution based on your required density, thickness, size, color and cutting requirements.
Whether you need large-format EPE foam sheets for further processing, custom-cut protective inserts or product-specific cushioning components, our manufacturing team can support B2B packaging projects from specification confirmation through production and export.
Contact Mailong Packaging to discuss your EPE foam sheet requirements and request a customized quotation.
