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Foam, glorious foam!

Molded foam end caps with a living hinge improve protection, increase warehouse space and reduce shipping costs for Hughes, a telecommunications satellite equipment manufacturer.

The molded foam end cap's living hinges allow it to store flat. During packaging, a line worker simply pulls up on the flaps, le
The molded foam end cap's living hinges allow it to store flat. During packaging, a line worker simply pulls up on the flaps, le

They say that necessity is the mother of invention, and about a year ago, Germantown, MD-based Hughes Network Systems became a believer.

Hughes learned that the material used by converter Packaging Strategies (Baltimore, MD) to create end caps for packaging and protecting Hughes’ sensitive satellite equipment was no longer available. Forced to investigate other options, the two companies worked together to design a stronger, seamless end cap made of Kaneka Texas’ (Houston, TX) Eperan® 1 ½-lb linear low-density polyethylene foam. The new end caps not only provided better protection for Hughes’ product, but also greatly reduced storage space and transit costs for the caps, thanks to a living hinge that allows them to remain flat until used.

Previously, Packaging Strategies was creating end caps for Hughes by laminating several ½” thick layers of extruded PE together. The two pieces that extended off each cap to buffer the sides of the equipment from its corrugated shipper were positioned in place as well.

When a dispute over a patent rendered the former material unavailable, Hughes and Packaging Strategies had intended to find another supplier of laminated PE for the end caps, but they changed their minds when they learned about Eperan PE 1.5. Eperan isn’t laminated, but instead employs a very thick skin on one side that allows it to be “kiss cut”, creating a living hinge. During the kiss cut, the material is die-cut almost completely through, stopping at the skin. The die-cut portions can later be folded out to allow the satellite equipment to be inserted. Hughes’ new end cap design incorporates these one-step, flexible hinges that can be easily activated by workers on Hughes’ manual packaging line.

Successful hinge

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