When the product inside can’t afford to fail, packaging becomes more than a box. It becomes part of the protection system.

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.