This month’s Product of the Month highlights one of Wasatch Container’s most engineered offerings: custom foam solutions designed to protect high-value, fragile, and mission-critical products in transit. From medical devices and aerospace components to military equipment and sensitive electronics, these solutions are built to perform when standard packaging falls short.

See Foam Solutions in action:

At Wasatch Container, foam is not treated as an afterthought. It is designed as part of a complete protective packaging system, engineered around the exact shape, weight, fragility, and shipping demands of the product inside.

Built for Protection

Every foam solution starts with the product.

Using custom fabrication and in-house design capabilities, Wasatch creates foam inserts that cradle, cushion, and secure products with precision. This reduces movement during transit, minimizes impact risk, and helps prevent the damage that leads to delays, returns, and added cost.

Unlike off-the-shelf inserts or loose-fill materials, custom foam is designed to match the exact needs of the application. That means better fit, better performance, and better protection.

Wasatch’s foam solutions are commonly used for:

• Medical devices
• Aerospace components
• Military and defense equipment
• Electronics
• Industrial parts
• Protective cases and reusable packaging systems

These are products where damage is not just inconvenient, it is expensive.

Precision That Performs

Wasatch’s foam solutions are produced using advanced converting equipment, including saws, die cutters, and high-pressure waterjet systems capable of cutting at up to 60,000 PSI. This allows for precise, repeatable cuts and complex multi-layer foam designs built for consistency and performance.

That level of precision matters.

It allows Wasatch to create highly customized inserts that not only protect the product, but also improve packing efficiency, reduce wasted material, and support better presentation when the package is opened.

More Than Foam

What makes Wasatch’s foam solutions different is that they are not built in isolation.

Because Wasatch also designs and manufactures corrugated packaging, wood crates, and protective cases, foam can be engineered as part of a complete integrated system. That means every layer of the package works together, from the outer shell to the interior cushioning.

This integrated approach gives customers better control over protection, packaging costs, and supply chain performance.

Sustainability Matters Too

Performance matters, but so does sustainability. Protective packaging should help reduce environmental impact without compromising product protection.

Wasatch has been recognized with the Pregis Renew Award three times, including in 2023, 2024, and 2025, for reducing carbon emissions by 35 metric tons through the use of recycled-content foam products. In 2025, company also earned the Pregis Recover Award after diverting 50,000 pounds of waste from landfills through its foam densifier recycling program.

These efforts reflect Wasatch’s broader commitment to smarter material use, internal recycling programs, and sustainable packaging practices that support both product protection and environmental responsibility.

The post Product of the Month: Foam Solutions appeared first on Wasatch Container.

When a local manufacturer began experiencing inconsistencies with their foam packaging, they came to us for support. What initially appeared to be a minor issue quickly revealed a larger disconnect between the packaging and the production process.

By taking a hands-on, performance-driven approach, we developed a solution that improved protection, consistency, and product integrity. Read this case study to see how we identified and solved the issue.

Looking Beyond Specifications

The challenge wasn’t that the packaging failed on paper, it wasn’t aligning with real-world conditions.

To solve the issue, we focused on how the packaging performed in use, not just how it was specified. Packaging today needs to function consistently across every stage of handling, storage, and transit.

We evaluated key factors, including:

• Repeated insertion and removal during handling
• Early-stage compression before shipment
• Foam density relative to product weight and geometry
• Cut tolerances allowing incremental movement over time

In many environments, a small failure rate may be acceptable. But for sensitive, calibrated components, even minor inconsistencies can create significant downstream issues.

A Performance-Driven Solution

It became clear that the issue wasn’t a single failure point, it was a misalignment between packaging design and performance requirements.

We redesigned the foam system to match the demands of the application. The foam geometry was refined to better support critical load points and control movement, while still allowing for efficient handling.

Where additional durability was required, we incorporated reinforced elements to improve structural integrity during repeated use.

We also optimized the foam material itself. By selecting a density better suited to the product’s weight and shape, we improved compression resistance without sacrificing flexibility. This ensured the foam maintained its protective properties throughout the product lifecycle.

Just as importantly, the design was aligned with how the product was actually handled, stored, and shipped, reducing variability and ensuring consistent positioning at every stage.

Validated in Real Conditions

Before full implementation, we tested the solution directly within the customer’s environment. This allowed us to validate performance under real handling conditions and make final adjustments based on actual use, not assumptions.

This hands-on approach ensures the packaging performs exactly as intended once deployed.

The Results

Following implementation, the customer experienced:

• Reduced product movement during handling and transit
• Fewer cosmetic defects and surface imperfections
• Improved consistency across shipments
• Lower rework and scrap rates

In high-performance applications, transit conditions are critical. We’ve developed similar solutions that reduce shock and vibration by up to 50%, helping ensure sensitive products maintain their integrity throughout the shipping cycle.

In many cases, optimized packaging design also leads to measurable operational gains, including up to 15% cost savings and 20% faster turnaround times.

Engineered for Performance

For high-value, precision products, packaging isn’t just about protection, it’s about performance. Even minor movement or impact can affect calibration, quality, and end-use reliability.

This is how we approach every project at Wasatch Container: engineering packaging solutions that protect, stabilize, and perform exactly as required, from initial handling through final delivery.

The post Customer Spotlight: Solving a Real Packaging Challenge appeared first on Wasatch Container.

From manufacturing and e-commerce to food, industrial products, and retail distribution, the RSC box is the most widely used corrugated packaging format worldwide. Its smart design makes it reliable, cost-effective, and easy to produce at scale, qualities that matter when products need to move safely from production line to final destination.

What Is an RSC Box?

An RSC (Regular Slotted Container) is a corrugated box where all flaps are the same length and meet at the center when closed. The box is typically manufactured flat, shipped efficiently, and then folded and sealed when needed.

This straightforward structure offers several key advantages:

• Efficient manufacturing and storage – RSC boxes ship flat and assemble quickly.
• Strong and reliable – corrugated structure protects products during shipping and handling.
• Versatile sizing – easily customized to fit almost any product.
• Cost-effective – optimized design reduces material waste and production costs.

Because of these benefits, the RSC has become the standard packaging solution across supply chains worldwide.

Built for Real-World Shipping Conditions

Packaging doesn’t just need to look good; it needs to perform. RSC boxes are designed to handle stacking, transport, warehouse storage, and delivery without compromising the product inside.

At Wasatch Container, we engineer RSC boxes with the right board grade, flute type, and structural design for each application. That means your packaging isn’t just a box; it’s a protective system tailored to your product and distribution environment.

Our team evaluates factors such as:

• Product weight and fragility
• Shipping distance and handling conditions
• Warehouse stacking requirements
• Sustainability and material efficiency

The result is packaging that performs reliably throughout the supply chain.

Customization That Supports Your Brand

While the RSC box is known for its simplicity, it also offers plenty of room for customization.

Wasatch Container works with customers to design boxes that support both protection and presentation. That can include:

• Custom sizing to reduce void space and shipping costs
• Flexographic printing for branding, instructions, or product information
• Specialty coatings or inks
• Structural inserts or partitions for additional protection

For many businesses, the shipping box is the first physical interaction a customer has with the brand. Even a standard RSC can become a powerful touchpoint when designed thoughtfully.

A Simple Design That Does a Big Job

The RSC box proves that great packaging doesn’t always have to be complex. Its straightforward structure, combined with strong corrugated materials and smart engineering, makes it one of the most reliable packaging solutions available.

At Wasatch Container, we take that proven design and tailor it to each customer’s product, logistics, and brand requirements.

Looking for a corrugated solution designed around your product? Our team at Wasatch Container can help engineer the right packaging to protect your products and support your operations from concept to delivery.

The post Meet the Product: The RSC Box appeared first on Wasatch Container.

Food & Beverage Packaging: Built to Perform

Food and beverage products face unique demands during handling, storage, and distribution. From temperature sensitivity and moisture exposure to stacking pressure and long transit times, packaging must perform consistently under real-world conditions.

Wasatch Container works with food and beverage manufacturers across the Intermountain West and beyond, applying proven U.S. best practices to ensure packaging supports safety, efficiency, and reliability at every stage.

Best Practice #1: Material Selection That Protects Product Integrity

In food and beverage packaging, material choice is critical. Corrugated packaging must provide strength while remaining suitable for food-contact environments. Foam components used for separation or protection must be clean, consistent, and appropriate for repeated handling.

Wasatch Container focuses on materials that deliver:

• Reliable compression strength for stacking and palletization
• Resistance to moisture and temperature fluctuations
• Clean, controlled manufacturing for food-related applications

Selecting the right materials helps reduce product damage, maintain quality, and support compliance throughout the supply chain.

Best Practice #2: Packaging Designed for Efficient Operations

Packaging doesn’t operate in isolation — it’s part of the production process. Best-in-class food and beverage packaging is designed to support speed, consistency, and ease of use on the line.

Wasatch Container engineers packaging to align with how products are packed, staged, and shipped. Proper sizing, consistent tolerances, and thoughtful internal support reduce slowdowns, limit product movement, and improve throughput without adding unnecessary complexity.

Best Practice #3: Strength for Distribution and Retail Handling

Food and beverage products often move through multiple touchpoints before reaching the shelf. Packaging must withstand repeated handling, stacking, and transportation while maintaining structural integrity.

Corrugated designs are engineered to manage compression loads and protect contents during long hauls and warehouse storage. For heavier or fragile items, foam inserts or reinforced structures help stabilize products and reduce the risk of damage during transit.

Best Practice #4: Sustainability Built into the Process

Across the U.S., sustainability continues to shape food and beverage packaging decisions. Reducing waste, improving recyclability, and using materials efficiently are now standard expectations — not extras.

Wasatch Container supports these goals by incorporating recycled corrugated materials, recyclable foam options, and efficient packaging designs that reduce excess material while maintaining performance. Smart design helps minimize waste without compromising protection.

Best Practice #5: Consistency and Quality Control

Consistency is essential in food and beverage packaging. Variability in box strength, fit, or internal support can create downstream issues in production and distribution.

With local manufacturing in Utah, Wasatch Container maintains tight quality control and responsive production schedules. This consistency helps food and beverage customers maintain reliable operations and meet delivery commitments.

Packaging That Supports the Bigger Picture

Food and beverage packaging plays a critical role in protecting products, supporting efficiency, and meeting industry expectations across the U.S. Best practices focus on performance, cleanliness, sustainability, and operational alignment — all areas where thoughtful packaging design makes a measurable difference.

Every day, more than 55 million tons of freight move across the United States, much of it food and beverage products that must arrive intact, uncontaminated, and on time. In a supply chain operating at this scale, packaging isn’t just a container — it’s a critical performance component.

At Wasatch Container, food and beverage packaging is built to perform under real conditions, supporting manufacturers with packaging that works as hard as the products it protects.

The post Food & Beverage Packaging Highlights appeared first on Wasatch Container.

Local Insight

From the Wasatch Front to remote distribution routes across Utah, Idaho, Colorado, and Wyoming, shipping conditions vary dramatically. Vibration from long hauls, compression during stacking, and exposure to dry climates or seasonal moisture all place stress on packaging. Wasatch Container approaches these challenges with a practical, performance-first mindset rooted in decades of manufacturing and design expertise.

As a Utah-based, family-owned manufacturer, Wasatch Container understands the realities of regional logistics. This local insight informs every design decision, from material selection to structural integrity, ensuring packaging holds up throughout transit, not just at the dock.

Engineering for Protection and Performance

Effective packaging begins with understanding the product and how it moves. Wasatch Container works closely with customers to evaluate product dimensions, weight, fragility, and shipping paths. Using advanced CAD design and prototyping, the team engineers corrugated boxes, foam packaging, and wood crates that support products through handling, transport, and storage.

Foam packaging is designed to absorb shock and reduce movement during transit, helping protect sensitive or high-value items. Corrugated packaging is engineered for strength, stackability, and efficiency, while wood crates provide durability for heavier or oversized products. Each format is designed with performance in mind, built to withstand real shipping conditions across the Mountain West.

Local Manufacturing, Reliable Lead Times

With design and manufacturing operations based in North Salt Lake, Wasatch Container provides responsiveness that out-of-region suppliers can’t always match. Local production means faster communication, shorter lead times, and greater flexibility when schedules shift or volumes change.

This regional presence also supports consistency and quality control. From initial concept through production, packaging is manufactured close to where many customers operate — reducing delays and helping keep supply chains moving smoothly.

Branding That Works as Hard as the Box

Packaging plays a role beyond protection. Wasatch Container offers high-quality print capabilities, including two-sided printing, allowing brands to create a substantial visual impact while maintaining structural performance. The result is packaging that protects products in transit and reinforces brand identity upon arrival, without compromising durability.

Sustainability with Practical Impact

Operating in the Intermountain West comes with a responsibility to the environment. Wasatch Container incorporates sustainable practices across its operations, including the use of recycled corrugated materials, recyclable foam options, and responsibly sourced wood. These efforts help reduce waste while maintaining the strength and reliability customers expect.

Packaging Design and Manufacturing Built in the region, for the region

For more than 30 years, Wasatch Container has supported manufacturers, distributors, and businesses shipping throughout Utah and beyond. Recognition such as Utah’s Best of State in Packaging reflects a continued commitment to quality, innovation, and dependable performance.

When products need to move through real-world shipping conditions, Wasatch Container designs and manufactures packaging to withstand the journey, from the first mile to the final destination.

The post Packaging Built for Real-World Shipping Conditions in the Intermountain West appeared first on Wasatch Container.

That philosophy guided the company’s decision to invest in a Kolbus RD115S rotary die-cutter in 2023. The installation gave Wasatch something few others in the Intermountain region could offer: high-quality, two-sided printing in one pass. “E-commerce has elevated packaging to a branding tool, and customers increasingly want the inside of the box to tell a story,” Frisch explained. “This investment allows us to help our customers create a more compelling unboxing experience.”

For Wasatch, the decision wasn’t taken lightly. The team conducted extensive due diligence, including print trials, before committing to the five-color press. The Kolbus RD115S has opened doors to serve brands that demand brochure-like interiors, special ink colors, and shorter run lengths. “It’s a space many large integrators avoid,” Frisch said. “But it’s where we thrive.”

Overcoming the Challenges of Two-Sided Print

Two-sided printing, however, came with challenges.  “Two-sided printing isn’t just about running a box through twice — it demands careful planning of graphics, ink, and board,” Frisch noted. Wasatch leaned on its production team, ink kitchen, and supplier partners to master the process. The payoff has been significant. “We’ve been able to consistently deliver two-sided print where many others struggle, and that consistency builds trust with our customers,” Frisch added.

A Partnership Beyond Equipment

For Operations Manager Martin Suhr, the Kolbus RD115S is only part of the story. Equally critical has been the partnership with SUN Automation Group, Kolbus’s North American partner. “The machinery is impressive, but what really sets the experience apart is SUN’s service,” Suhr (pictured left) said. “Their depth of experience and the caliber of their people give us confidence that no matter the challenge, we’ll have the support we need.”

That support has proven critical and hands-on, with SUN and Kolbus technicians working alongside Wasatch staff during commissioning and troubleshooting. “It was a true partnership in action,” Suhr recalled. “Everyone was responsive, engaged, and committed to finding a solution. That kind of service is what makes us successful long term.”

Positioning for the Future

Phil Eads, Technical Sales Manager at SUN Automation, said Wasatch’s early adoption of two-sided print is a case study in how independents can stay competitive.“Wasatch Container has embraced two-sided print in a way few companies have, and the results speak for themselves. They’re not just meeting demand—they’re shaping it.”

Looking ahead, Wasatch plans to continue its growth in specialized packaging while exploring fulfillment services for entrepreneurial brands.

“We don’t want to be the biggest,” Frisch emphasized. “We want to be the best. And that means continuing to invest, innovate, and partner with organizations like SUN and Kolbus that share our commitment to excellence.”

Article shared by The Packaging Portal

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As we move into 2026, the packaging landscape is transforming faster than ever. Consumer expectations are shifting, digital and physical experiences are colliding, and sustainability is influencing how brands design, ship, and communicate. What happens next will affect not only packaging but also supply chains, brand trust, and customer loyalty.

Here’s what will define 2026 and how Wasatch is already building toward it.

Transparency Becomes a Brand Strategy

More than ever, customers want to understand where materials come from, how responsibly they’re produced, and whether packaging truly aligns with a brand’s values. Transparency has become a core component of brand trust, and packaging plays a central role in communicating that integrity.

This is especially true for critical, high-performance industries such military, aerospace, medical, industrial, where traceability, accuracy, and adherence to strict specifications are essential. Packaging must demonstrate reliability, compliance, and accountability at every stage.

At Wasatch, we’re proud to partner with these sectors. As the Intermountain West’s authorized distributor of Pelican and SKB protective cases, we support industries where transparency isn’t just preferred, it’s required. Aviation components, field equipment, high-value instruments, and mission-critical technologies all rely on packaging that performs exactly as promised.

Transparency isn’t just a trend for these industries; it’s part of the responsibility we share in protecting what matters most.

Sustainability Evolves From Feature to Foundation

Recycling and lightweighting were once differentiators. In 2026, they are the baseline.

The next era of sustainability will emphasize:

• Material efficiency without sacrificing performance
• Designing smarter, not simply “using less”
• Responsible production that reduces environmental impact

At Wasatch, sustainability is built into every division. We offer recycle-ready corrugated packaging and were proud recipients of the Pregis Renew Award, recognizing our ongoing commitment to actively reducing carbon emissions by choosing packaging solutions with recycled content.

Our foam packaging is engineered with 60% post-industrial content, significantly reducing virgin material use while maintaining the protection customers expect. Stronger foam means fewer product failures, fewer reships, and a smaller environmental footprint.

To extend lifecycle value, our repair and refurbishment program keeps our crates in service longer, reducing waste and giving customers a sustainable, cost-effective alternative to replacement.

The Unboxing Experience as a Competitive Advantage

Packaging isn’t just delivering a product, it’s delivering a first impression. In 2026, unboxing will shift toward intentional structural design that blends:

• Premium presentation that elevates perceived value from the moment the box is opened
• Purpose-driven graphics and messaging that guide, inform, or surprise the end user
• A seamless transition from transit to display, minimizing setup and maximizing impact
• Strategic internal organization, ensuring components are arranged cleanly and logically
• Material and finish choices that reflect brand identity without adding unnecessary waste

This trend is especially powerful in retail displays, promotional kits, premium goods, and branded experiences.

Building the Next Era of Packaging

As we step into 2026, Wasatch Container brings forward three decades of expertise, facility reinvestment, and a commitment to innovation across every division from corrugated and foam, to displays, protective cases, and beyond.

The next chapter of Packaging Reimagined starts now.

The post What’s Ahead in Packaging for 2026 appeared first on Wasatch Container.

Here’s how we make it happen.

1. Design & Discovery

Every great package starts with a conversation. We want to understand your product, your brand, and what makes it unique. Whether you’re launching something new or fine-tuning an existing design, our team rolls up their sleeves to help you find the right fit.

Using advanced CAD tools, we develop 3D concepts and prototypes so you can see and test exactly how your packaging will perform in the real world. From choosing materials to balancing protection, appearance, and cost, every decision is made with your goals in mind. Because great packaging doesn’t just hold your product, iit represents it.

2. Straightforward Pricing

No surprises here. Once your design is finalized, we’ll provide clear, competitive pricing that’s easy to understand.

Whether you need short runs, ongoing programs, or just-in-time inventory, we’ll walk you through the options that make sense for your business. Our goal is to keep things simple, efficient, and right-sized, so you always know what to expect.

3. Production & Precision

This is where ideas take shape. Our Salt Lake City facility houses corrugated, foam, and wood manufacturing all under one roof, giving us complete control from start to finish.

You can see the pride in every detail, from the first cut to the final load-out. Our state-of-the-art equipment keeps production fast and accurate, while our local team ensures quality that holds up shipment after shipment. The result? Packaging built to perform, every time.

4. Service That Sticks Around

When your order ships, our work isn’t over. Our team stays connected, ready to help with reorders, new projects, and anything else you need.

Because at Wasatch, service isn’t a department, it’s who we are. Many of our customer relationships span decades, and that’s something we’re proud of.

Let’s Build Something Great Together

Wasatch Container is a family-owned, independent manufacturer that’s been part of the Utah business community for more than three decades. We’re here for the long haul to create packaging that protects your products, elevates your brand, and supports your growth.

Ready to get started? Contact us today to talk about your next project.

The post How Wasatch Container Brings Packaging to Life appeared first on Wasatch Container.

At Wasatch Container, we combine design expertise with performance testing to create foam packaging that performs under real-world conditions. Using ASTM D4168 testing standards such as drop tests, G-force measurement, and energy absorption curves, we evaluate how each design absorbs impact to ensure your products arrive safely every time.

Selecting the Right Foam

Each foam material offers unique benefits and choosing the right one depends on how it needs to perform.

• Polyethylene (PE) is dense, resilient, and resistant to water and chemicals, making it ideal for reusable crates and heavy-duty applications.
• Polyurethane (PU) provides softer cushioning for delicate electronics or medical devices that require gentle handling.
• Expanded Polystyrene (EPS) offers a lightweight, cost-effective option for single-use packaging.
• Anti-static foam prevents electrostatic discharge, protecting sensitive electronic components.
• And for a refined finish, cross-linked PE (XLPE) delivers strength, smooth texture, and lasting shape, perfect for automotive, optics, or high-value goods.

Engineered with Precision

We’ve invested in advanced equipment to ensure every insert fits and functions perfectly from design to final assembly. Each machine plays a key role in creating packaging that protects, presents, and performs.

• Waterjet Cutting – Using a high-pressure stream of water, our waterjet machines cut through foam with ultra-precise accuracy — achieving tolerances as tight as ±1/32”. This process creates clean edges and intricate shapes without heat distortion, ideal for high-end or delicate components.
• CNC Routing (Computer Numerical Control) – Our CNC routing technology uses computer-guided cutting to carve custom cavities and layered builds with pinpoint precision. This product is perfect for items requiring snug, repeatable fits across multiple layers of foam, ensuring consistent protection and presentation.
• Hot Wire & Die Cutting – For larger runs or uniform shapes, these cutting methods deliver efficiency and consistency. The hot wire allows for smooth contour cuts on expanded foam materials, while die cutting is used for repetitive precision at scale.
• Adhesive Lamination – When projects demand multiple layers or varied foam densities, our lamination system bonds them seamlessly. The result is multi-layer protection that combines rigidity, cushioning, and durability, all in one engineered solution.

We also offer kitting and assembly to create complete, multi-component systems that look professional and perform reliably.

Protection That Performs

Foam packaging does more than protect, it improves efficiency. Lightweight materials help lower freight costs, while custom inserts streamline packing and elevate product presentation.

For over 30 years, Wasatch Container has delivered proven packaging performance through innovation, precision, and craftsmanship. Whether you need reusable crates, custom inserts, or high-end presentation packaging, our foam solutions are built to protect every shipment, every time.

Contact us today to learn more about our engineered foam packaging solutions.

The post Innovative Foam Packaging Solutions for Fragile Goods appeared first on Wasatch Container.

Guests had the opportunity to tour both of our facilities: our Corrugated Plant and our Protective Packaging Division, gaining a firsthand look at how we design, manufacture, and deliver packaging that keeps supply chains moving. Along the way, visitors tested their knowledge in trivia games about our machines, chatted with industry peers, and discovered more about what sets Wasatch apart.

Of course, it wouldn’t be a Wasatch celebration without some fun and a nod to our roots in 1995. Guests enjoyed toy car racing, virtual golf, and plenty of photo opportunities with a retro 90s twist, complete with sweet treats and toys. A delicious lunch brought everyone together, fueling great conversations and lasting connections.

We’re incredibly grateful to everyone who joined us to mark this milestone. Your support, energy, and partnership made the day truly special and serve as a reminder of why we’ve been committed to quality, service, and reliability for three decades strong.

If you enjoyed your time with us, we’d love to hear about it! Please consider leaving us a Google Review to share your experience. Your feedback helps us continue raising the bar for the next 30 years.

Thank you for celebrating with us. We couldn’t have done it without you. 

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