Airworthy packaging has to do two contradictory things: survive air-cargo handling, and weigh almost nothing — because on air freight you are billed on dimensional weight, not actual weight. Foamtech engineers ultra-light EPE foam and air bubble packs from densities as low as 15 kg/m³, cutting chargeable weight against wood and PU while still passing multi-leg handling. Made at our own plant in RIICO Bhiwadi, on the doorstep of the Neemrana–Bhiwadi–Bawal export belt.
Airlines charge on whichever is greater: actual weight, or volumetric weight calculated from the outer dimensions of your pack. A wooden crate loses on both counts — it is heavy and bulky, and the timber does nothing your foam insert could not do at a fraction of the mass. Every kilogram and every centimetre you remove from the pack comes straight off the freight invoice, on every single shipment, for the life of the part.
Our plant sits at E 926, Phase III, RIICO Industrial Area, Bhiwadi — inside the industrial belt that feeds most of north-west India’s air-freight exports. That matters for airworthy work specifically, because engineered packs need iteration: a sample, a trial pack, a re-cut. Being an hour away rather than a day away is the difference between resolving that in a week and resolving it in a month.
| EPE foam sheets | 0.85–120mm, 15–35 kg/m³. The 15 kg/m³ grade is the workhorse of airworthy design — lowest mass per unit of cushioning. |
|---|---|
| EPE foam profiles | U-channel, L-angle and corner blocks for edge and corner protection without adding a full crate. |
| Air bubble rolls | 300–2200mm, 6/10mm bubbles, 30–80 micron — surface and void protection at near-zero weight. |
| EPE foam pouches | 1–6mm tear-resistant pouches for individually wrapped components. |
| Anti-static (ESD) grades | Pink ESD foam for avionics, electronics, sensors and instrumentation shipments. |
| Laminations | Foil and HDPE barriers for moisture and condensation on long-haul, multi-leg journeys. |
| Engineered die-cut sets | Designed to your part drawings on in-house hydraulic punching. Prototype within 48 hours. |
We do not quote airworthy packaging from a catalogue, because the saving lives in the geometry of your specific part. The process is short and deliberately practical:
Send part dimensions and your current pack weight. We will engineer a lighter airworthy pack and quote within 2 business hours.
Airworthy packaging is protective packaging engineered specifically for air freight: light enough to minimise dimensional (volumetric) weight charges, strong enough to survive air-cargo handling, and compliant with airline and customs requirements. Foamtech builds airworthy packs from lightweight EPE foam and air bubble materials, with optional foil or HDPE lamination.
Yes. Our plant is at RIICO Bhiwadi, roughly 55 km from Neemrana on NH-48, and we supply the Neemrana RIICO estates, the Japanese Investment Zone, Ghiloth, Shahjahanpur and Behror. Standard sizes dispatch same-day; engineered die-cut packs follow 48 to 72 hours of production.
Yes. Our factory is inside the RIICO estate at Bhiwadi, so Bhiwadi exporters can collect the same working day. Bawal and Khushkhera are both within our routine daily delivery radius, and we serve the auto-ancillary and engineering exporters across that belt.
It depends entirely on what you are replacing and the geometry of the part. Swapping a wooden crate and PU blocks for an engineered EPE foam set typically removes a substantial share of both mass and outer volume — we have seen reductions of up to around 40% in chargeable weight. We model the specific figure for your part before you commit, rather than quoting a generic percentage.
Three reasons. EPE foam packs weigh a fraction of timber, which directly cuts air-freight charges. They need no ISPM-15 heat treatment or fumigation certificate, avoiding customs delays. And closed-cell foam gives better shock cushioning per gram than timber, so damage claims fall as well.
Yes. Pink anti-static (ESD) EPE foam is available across the full density range, in sheets, pouches and die-cut inserts — suited to avionics, sensors, instrumentation and other static-sensitive air shipments.
Yes. Share part drawings or a sample and our in-house R&D team engineers a die-cut foam pack, delivers a prototype within 48 hours, and validates it against your drop and vibration requirements. The tooling is retained for repeat orders.
No. ISPM-15 applies to solid wood packaging material, which must be heat-treated or fumigated and stamped. Polymer foams such as EPE fall outside that requirement entirely, which is one of the main reasons exporters move away from wooden crates for air freight.