Inner Tray Materials Guide

Everything on inner trays, foams, blister packs, and pulp molds.

Market Analysis of Common Insert Tray Materials

⭐⭐⭐⭐⭐ Mainstream Materials

Market share: over 80%

• EPE foam (40%)

• Corrugated board (25%)

• EPS foam (20%)

• EVA foam (15%)

• Thermoformed plastic (12%)

⭐⭐⭐ Specialist Materials

Market share: around 15%

• Flocked inserts (premium products)

• Polyurethane sponge (precision instruments)

• Non-woven fabric (apparel and footwear)

• Molded pulp (eco requirements)

⭐⭐ Emerging Sustainable Materials

Market share: around 5%

• PLA biodegradable materials

• Starch-based materials

• Honeycomb board

• Bamboo fiber composites

Detailed Analysis of Mainstream Insert Materials

✨ EVA Foam Insert

Premium feel, strong protection

Foamed from ethylene-vinyl acetate copolymer, with excellent physical and chemical properties — light, soft and resilient.

• Density: 0.035-0.18 g/cm³

• Rebound rate: ≥85%

• Cost: $2-8/dm³

• Market share: 15% (mid-to-high-end products)

• Applications: premium electronics, precision instruments

• Traits: antistatic, chemically resistant

💎 EPE Foam Insert

Great value, good cushioning

Foamed from low-density polyethylene resin with a distinctive bead structure — an eco-friendly packaging material.

• Density: 0.018-0.035 g/cm³

• Rebound rate: ≥90%

• Cost: $0.8-2.5/dm³

• Market share: 40% (the most frequently used)

• Applications: appliances, consumer electronics, craft goods

• Traits: 100% recyclable, excellent value

🔍 Thermoformed Insert

High forming accuracy, clear and attractive

A thermoforming process where heated plastic sheet is vacuum-formed; commonly PET, PVC and PS.

• Thickness: 0.15-2.0 mm

• Clarity: ≥85% (clear grades)

• Cost: $1.5-6/dm²

• Market share: 12% (the mainstay of clear packaging)

• Applications: consumer electronics, cosmetics, food

• Traits: transparent display, precise forming

📐 Folded Cardboard Insert

Ingenious structure, attractive printing

High-quality board with precise structural design and folding, forming a protective packaging insert.

• Grammage: 250-600 g/m²

• Whiteness: ≥80% ISO

• Applications: premium gifts, cosmetics, tea

• Traits: excellent print results, fully customizable

📦 Corrugated Cushioning Insert

Light yet strong, with good cushioning

Made from single- or double-faced corrugated board; the fluted structure delivers excellent cushioning and load capacity.

• Types: 3-, 5- and 7-ply corrugated

• Thickness: 3-15 mm

• Applications: appliances, logistics, building materials

• Traits: lightweight and economical

🌱 Molded Pulp Insert

3D forming, compostable

Made from pulp via a dedicated molding process — screened, dewatered, formed and dried into a three-dimensional pack.

• Density: 0.3-0.6 g/cm³

• Decomposition: 45-90 days (composting conditions)

• Applications: electronics, food, medical supplies

• Traits: 100% natural, degrades quickly

Material Selection Guide

Product Type	Recommended Material	Primary Consideration	Alternative
Precision Electronics	EVA Foam	Antistatic, precision protection	EPE Foam
Mid/Low-End Electronics	EPE Foam	Value for money, cushioning	Corrugated Cushioning
Products Needing Visibility	Thermoformed Insert	Clarity, appearance	EVA Foam
Premium Gift Packaging	Folded Cardboard	Print result, brand image	EVA Foam
Transport Packaging	Corrugated Cushioning	Light weight, cost control	EPE Foam
Sustainability-Driven Products	Molded Pulp	Biodegradable, sustainable	Folded Cardboard

Cost-Benefit Analysis

Relative Cost (low → high)

1. Corrugated cushioning → EPE foam (economy)

2. Folded cardboard → thermoformed insert (mid-range)

3. Molded pulp → EVA foam (premium)

Sustainability Ranking

1. Molded pulp — 100% natural, degrades quickly

2. Folded cardboard — recyclable and biodegradable

3. Corrugated cushioning — recyclable, green and economical

Practical Selection Advice

Budget first:EPE foam or corrugated cushioning — low cost with adequate protection
Brand image:EVA foam or folded cardboard lifts the perceived tier and the unboxing experience
Sustainability requirements:Molded pulp is the first choice and aligns with sustainability goals
Product visibility:Nothing replaces a thermoformed insert for showing product detail
Volume production:Account for tooling amortization — EVA and molded pulp suit large runs
Multi-function needs:Folded cardboard allows tiered storage and uses space most efficiently

Industry Trends

Technology Directions

Bio-based materials: degradable options such as PLA and PHA
Nanotechnology: modifying traditional materials for better performance
Smart materials: temperature and humidity indication
3D printing: personalization and rapid prototyping

Market Outlook

Rising environmental awareness: growing demand for degradable materials
Personalization: a shift toward small runs and many variants
Cost optimization: automation reduces labor cost
Regulation: plastic restrictions accelerate new materials

Detailed Technical Comparison

✨ EVA Foam Insert — Detailed Specifications

Physical Properties

• Density: 0.035-0.18 g/cm³

• Hardness: Shore C 15-45

• Compressive strength: 0.3-1.5 MPa

• Rebound rate: ≥85%

• Tear strength: ≥2.5 N/mm

• Tensile strength: ≥0.8 MPa

Environmental Tolerance

• Service temperature: -40°C to +80°C

• Water absorption:<1%

• UV resistance: does not age in long-term use

• Chemical resistance: suits a wide range of environments

• Antistatic: suitable for electronics

Application Advantages

• Smooth, fine surface with a premium feel

• Available in many colors for strong visual effect

• Precise machining for an exact fit

• Supports complex geometry

• Long tool life and high throughput

💎 EPE Foam Insert — Detailed Specifications

Physical Properties

• Density: 0.018-0.035 g/cm³

• Tensile strength: ≥80 kPa

• Compressive strength: ≥50 kPa

• Rebound rate: ≥90%

• Thermal conductivity: 0.034 W/(m·K)

Safety and Environment

• Water absorption:<0.1%

• Fire rating: class B1 (flame retardant)

• Service temperature: -60°C to +80°C

• Non-toxic and odorless, food-grade compliant

• 100% recyclable

Cost Advantages

• Low raw material cost

• Simple processing

• Reusable

• Stable supply chain

• Well suited to large runs

🔍 Thermoformed Insert — Detailed Specifications

Forming Parameters

• Thickness range: 0.15-2.0 mm

• Forming accuracy: ±0.1 mm

• Tensile strength: 40-60 MPa (PET)

• Clarity: ≥85% (clear grades)

• Temperature range: -20°C to +60°C

Material Characteristics

• PET: eco-friendly, high clarity, heat resistant

• PVC: low cost, easy to process, tough

• PS: high rigidity, good formability

• PP: food grade, strong chemical resistance

• Oxygen transmission rate:<0.1cc/m²·day·atm

Application Traits

• Perfect for transparent display

• Can carry printed graphics and text

• Formed in one pass with high throughput

• Structurally stable and impact resistant

• Ideal for precise product location

Quality Standards and Test Methods

Physical Property Testing

Density Test

GB/T 6343-2009 — determination of apparent density of cellular plastics and rubbers

Compressive Strength

ASTM D1621 — compressive properties of rigid cellular plastics

Resilience

ASTM D3574 — standard test methods for flexible cellular materials

Safety and Environmental Certification

Food Contact Certification

• FDA (US Food and Drug Administration)

• EU 1935/2004 (EU food contact materials regulation)

• GB 4806 series (China food safety standards)

Environmental Certification

• FSC (Forest Stewardship Council)

• PEFC (Programme for the Endorsement of Forest Certification)

• Cradle to Cradle

Supplier Selection and Sourcing Guide

Supplier Evaluation Criteria

• Production capacity:Annual output, equipment level, technical capability
• Quality system:ISO certification, quality processes, test equipment
• Delivery capability:On-time rate, inventory management, logistics network
• Cost competitiveness:Transparent pricing with a sound cost structure
• Service level:Technical support, after-sales service, responsiveness

Sourcing Considerations

• Sample approval:Request samples and test them in practice
• Clear specifications:Detailed technical parameters and quality requirements
• Price breakdown:Understand material, process and tooling costs
• Lead time:Plan production cycles and inventory sensibly
• Quality assurance:Establish quality standards and inspection procedures

Cost Optimization Strategies

• Bulk purchasing:Plan order quantities to bring the unit price down
• Standardized design:Reduce customization and use common specifications
• Material selection:Balance performance requirements against cost
• Process optimization:Simplify the workflow to improve efficiency
• Long-term partnerships:Build strategic supplier relationships

Typical Industry Case Studies

📱 Electronics — Premium Smartphone Packaging

Solution

• Main protection: EVA foam insert, precision cut to the phone profile
• Accessory retention: small thermoformed trays for charger and cable
• Antistatic handling: antistatic materials throughout to protect components
• Presentation: black EVA foam raises the premium feel

Results

• Transit damage rate:<0.1%
• Unboxing satisfaction: 95%+
• Packaging as share of cost: 2-3%
• Brand image lift: significant

💄 Cosmetics — Fragrance Gift Set

Solution

• Premium design: folded cardboard insert printed with brand logo and pattern
• Tiered storage: a multi-level structure holding the fragrance and testers separately
• Material upgrade: 250 g white card with UV varnish for a better feel
• Sustainability: FSC-certified paper in line with sustainability goals

Business Value

• Brand awareness lift: 30%
• Repeat purchase growth: 25%
• Social media sharing: markedly higher
• Cost increase: only 10-15%

🥚 Food — Organic Egg Packaging

Solution

• Sustainable material: molded pulp insert, 100% biodegradable
• Precision forming: an individual pocket per egg to prevent collisions
• Cushioning: a multilayer fiber structure absorbs transit shock
• Breathable design: keeps eggs fresh and extends shelf life

Environmental Benefits

• Carbon footprint reduction: 60% (vs. plastic packaging)
• Decomposition: 45-60 days
• Breakage reduction: 80%
• Raises consumer environmental awareness

🔗 Related Topics

🏗️ A Professional Guide to Insert Tray Styles and Structural Design

An in-depth technical guide to insert structure categories, manufacturing processes, functional characteristics, special structure case studies and engineering calculations.

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