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Do you know the real cost of damage?

The fact of the matter is that nearly 10% of all packages shipped are damaged during transit. And, of those damaged packages, approximately 5% have product damage.

OK, you’re probably thinking that that small a percentage of damage products doesn’t really add up to that much. However, the real cost is an astonishing $2.05 billion in unsaleable items. Sure, not every unsaleable item is due to damage, but when it’s a portion of a number in the billions, it’s still too much.

But it isn’t just the cost in actual dollars and cents. There are other significant costs to shipping damage, including drops in quality delivery metrics, decreases in customer perception of your brand, and loss of customers.

Through our client collaborations we’ve accrued hundreds of real world studies with valuable comparison data. Because we believe it’s our responsibility to ensure existing and potential clients have easy access to core concepts, we’ve compiled this fact sheet as a foundation. It's more than enough to get started.

And, honestly, that's the most important part of the journey.

Some things are clear

In the face of increasing shipping rates and reports of product damage, it's critical to understand what customers expect.

  • The right packaging pleases shoppers, lowers shipping costs, and reduces returns of damaged purchases.
  • Containers should be rigid and large enough to allow room for adequate cushioning material on all sides of the contents.
  • Fragile articles should be wrapped separately. Each piece needs proper separation from each other and clearance from the corners and sides of the box. Glass items, for example, must not touch other glass items.
  • Impressive packaging will differentiate retailers who want to create loyal brand advocates, offering a retailer an advantage over 80% of the market.

To keep it simple, as logistics shippers switch to density-pricing, retailers are best advised to select quality containers sized to pricing. They are smart to insulate and protect contents in the most cost efficient and secure way. If less is more, then Foam in place makes the most sense.

Understand your customers' values

Customers have the reasonable expectation that their purchase will arrive on time and in complete working order. Regardless of the ecommerce retailer, customers expect products to be damage free. Their expectations seem to have risen with the aggressive approach of online sources – and they are will and able to voice their dissatisfaction.

Consider this: a 2014 study showed that only 5% of consumers feel their customer experience exceeded their expectations and approximately 30% say that companies miss the mark.

But more concerning than those statistics are that customers now feel empowered to complain about their dissatisfaction:

  • 95% of customers will report their poor experiences to others some of the time.
  • 60% of consumers will report their poor experiences to others all of the time.
  • On average, consumers tell 8 people about their good experiences, but more than TWICE that many about their bad experiences.



The fundamentals of Damage

Damage affects the customer. The buying experience dramatically improves when they open the package to discover products exactly as they are expected to appear.

Let's just be honest

Any one of us would be more likely to understand damage to a paperback book we ordered off of Amazon over the newest iPhone we ordered from our cellular provider. It no longer makes sense for retailers to simply increase the size of the package in order to improve protection; in shipping dimensional weights matter more than actual weights, so retailers must take into account their customer’s needs and interests as they consider their packaging.

But, no matter what: every package will still have the same likelihood to incur that 10% of damage.

The customer is king.

Customer satisfaction is relative to the size and price of the products that they are having shipped. The more money they spend, the more likely they are to be concerned about the potential for damage. And knowing that they can return a product will do nothing to alleviate the anxiety and negativity they will feel should they need to exercise that capability.

Consumers have reasonable shipping expectations:

  • Deliver ordered items in a high-impact and long-lasting comfort cushion
  • Wraps the product without hiding it in annoying loose fill
  • Secure the item with less product and something that is a sustainable solution
  • Protect fragile, odd-sized, and odd-shaped products
  • Reduce the worry about product performance and the need to return
  • Lower or maintain current customer share of shipping cost

Easy access to purchase and parts with the hassle of foam peanuts and bubble wrap is also a real plus, as is the easy removal of contents with the hassle of containers within containers. And easily recyclable materials make everyone a little happier.

To keep it simple, as logistics shippers switch to a density price model, retailers are best advised to select quality containers. They are smart to insulate and protect contents in the most cost efficient and secure way.

Sometimes only custom protection will work

That's exactly what Foam in Place packaging provides: customized protection.


Foam in place packaging provides unique customized cushioning properties. It is very versatile because it “molds” around the product being packaged. The insert is actually made from chemicals injected into a high density polyethylene bag. Once mixed together, they begin to foam up, expanding to surround the item and fill the outer container.

Foam in place is an ideal material for companies shipping many different configurations of fragile products . It fills the space fully with a customized cushion that molds itself around the product it is protecting – sharp edges, corners, odd shapes, and all. The product is securely seated in a pocket of protection.

Foam in place packaging technology offers the highest degree of product protection available. It allows operators to work smarter and more simply for maximum productivity while reducing or eliminating damage expenses. And its small footprint maximizes space and cost efficiency, as well as increases consumer confidence.

If you’re constantly trying to manage consumable usage, frustrated by unexpected equipment downtime, or annoyed about having to wait days for a technician, you’re not alone. The fact is that equipment is supposed to help make packaging easier, safer, more efficient, and keep your facility more productive.

Today, the most cost-effective and time-efficient foam in place technologies are designed with the operator in mind, by simplifying the packaging process, reduce costs, and increasing productivity.

These technologies include ways to:

  • Better manage costs associated with consumables
  • Avoid downtime due to equipment malfunctions
  • Operate the unit quickly, easily, and by any employee, not just highly trained ones
  • Know that every package going out the door has the right level of protection
  • Use new, state-of-the-art equipment without a huge capital expenditure

As basic as it might sound, these weren’t really a possibility until recently. Many facilities were using 20th century technology to package 21st century products because they were trying to avoid spending extra capital on upgrading their packaging.

But sometimes it takes moving your packaging into the 21st century to ensure that your products arrive to your customers undamaged and that your brand and reputation are not tarnished.


In the same way that your car can most likely alert you to a potential maintenance issue before a catastrophic failure, so to can many of the newest models of foam in place equipment. Designed to monitor, collect, and measure critical information, such as foam and film usage, temperature, pressure, etc. each time it is operated, this system ensure that the machine stays up and running to your custom specifications. Any potential issues are automatically relayed back to your equipment provider’s service team and a technician is dispatched to fix the problem before it becomes one.

This seemingly simple feature allows you to:

  • Increase productivity
  • Optimize equipment performance
  • Stay ahead of problems and costly downtime

By being proactive, systems can optimize uptime and ensure that proper system maintenance is performed.


For companies with multiple products of varying size and shape, a barcoding “smart” feature helps take the guesswork out of what bag to use and how much foam to use.

During the packaging process, operators simply scan the bar code label (for the specific product) using a hand wand. The system is programmed to automatically dispense the precise amount of foam and film needed for the optimal pack-out of each product based on its unique barcode.

The process is simple, automatic, and ensures that your bottom line is as protected as your product by increasing productivity, improving protection, and reducing material waste.

Equipment Design

The worst part about trusting your packaging line to machines? The downtime when they breakdown. And, inevitably, something will happen and a part will need to be replaced. With traditional machines, replacing parts can take up to an hour. And who has that kind of time to spend on a machine, especially when you need to be pushing products out the door. With the newest technological advances in Foam in place packaging, part replacements can take mere minutes and quick and easy film roll loading is done via loading arms that take the potential for employee strain injury out of the equation.

The Pregis® systems lead and define the field:

  • SmartMold™ - In pre-mold applications, foam is dispensed into a bag molded over a wooden custom form. This creates a shaped cushion for use with specific products.
  • SmartBagger™ - The operator creates a foam cushion for the bottom of the container. The product is laid on the cushion before a second cushion is placed on top, filled with foam, and sealed, making a "sandwich" with the product secured in the middle.
  • SmartShot™ - The operator lines a box with film, fills the box with foam, and wraps the film over the product like a blanket.
  • SmartShot-Hybrid™ - The machinist fills a bag with foam and places product on top. Once it expands, a second bag forms a custom lid.

But where do these machines really make the most sense?

  • Home-based businesses are especially cost-bound to packaging and ship safely and efficiently.
  • Furniture and appliances are heavily discounted when they have surface scratches.
  • Shipping stores and business mailrooms ship with various options, but they rely on the low cost, speed, and minimal space of shipping equipment and supplies.
  • Retail and e-commerce have new reasons to consider the value of “free” shipping offers.
  • Museums and antiques need protection for sensitive and fragile materials.
  • Medical products should arrive cleanly, as well as safely.
  • Electronics include sensitive parts and glass requiring protection and separation.

The Customer-focused commitment

Smart shoppers spend where they trust performance. When undamaged packaging means undamaged goods, customers have a reasonable expectation for quality packing and shipping.

The Pregis® Promise

We represent the leader in Foam in place technology. Pregis® US offers smart technological solutions for smart business needs with IntelliPack® Advantage programs that promise:

  • Custom programs designed to customer-specific needs
  • Installation, training, and sustaining support
  • All parts and labor required
  • Telemetry preventive maintenance and bar coding
  • Automatic upgrades on mechanic and software
  • Continuing expert consultation on changing packaging needs
  • Lifetime warranty on all parts and equipment

Pregis® promises "Foam in place Solutions with a High IQ." The Pregis® labs offer state-of-the-art equipment and advice for design and testing of density, compression, tensile strength, and more.

  • No up-front capital investment and minimal installation impact.
  • Cellular telemetry lets the application systems monitor their own performance, tracking the use of consumables, and automatically reordering supplies to avoid costly downtime.
  • Bar-coding lets operators deliver consistent packaging protection, even on diverse product lines, ensuring protection with the right amount of film and foam each application.
  • User-friendly control panels, on-site training, and responsive customer service keep operation simple and learning curve short.
  • System footprint and energy usage are low, and supplies can be stored simply and ordered automatically to limit storage space.

Our Customer Commitment

You want someone who will work on your behalf. So, rest assured, we have our customers at the forefront of every thought and we treat every customer like they are the only customer.

We start by performing an on-site assessment of your current packaging and logistics operations to help identify the costs and inefficiencies that are plaguing your high-volume operation. You probably know that there are issues; let our dedicated professionals, with dozens of years of industry experience, tell you exactly what those issues are.

From there, we can help assess the right way to solve those issues. With design labs and highly trained packaging engineers on staff, we will work to identify specific technical requirements for your applications and develop custom packaging solutions based on comprehensive needs analyses. It will be science and math – engineering at its finest – that provide the right solutions to your on-site problems.

Once we’ve determined the right solution, our training team will work directly with you to ensure that your packaging operations are back online quicker and more productively than ever before.


We've given you the basics, and you're well on your way to making some very smart decisions about damage prevention. Now is the time to dive deeper with one of our dedicated and knowledgeable Product Specialists.

Intelligent Foam in Place Packaging

Our foam in place products are “smarter” than the competition. The Intellipack products we carry have the high quality foam protective packaging product of Instapak by Sealed Air, but are enhanced with the intelligence factor of Pregis. Described as “Foam in Place Systems with a high IQ,” Intellipack separates itself from the mold by providing an innovative telemetry and bar-coding system.

Foam in place Features: Superior Features

Our company has been in the business of providing packaging supplies and solutions for over 30 years. Foam in place Systems offers excellent customer service and top quality foam-packaging products. Our main goal is to provide you with the most customer-friendly, innovative foam packaging solution on the market. With better foam packing technology, we are one step ahead of the competition with our five degrees of intelligent packaging.

5 Degrees in a Nutshell:

Another benefit of our Foam in place products is The Five Degrees of better packaging intelli-gence that comes with each product. These five degrees separate us from the competition by en-suring accountability, increasing technology and providing quick resolutions to your company's needs.

1. Telemetry

The intelligence of telemetry enables preventative maintenance 24 hours a day, seven days a week. By providing an automatic ordering option and simple connectivity, this Foam in place packaging system enables greater efficiency; therefore, reducing your overall raw material costs. The telemetry system automatically collects, monitors and measures liquid foam and film usage, pressure, temperature and other system maintenance issues. It will then automatically contact a service technician to make sure your machine gets everything it needs to be up and running at all times.

2. Barcoding

The simple, automatic, intelligent process of bar coding increases your productivity, improves your protection and reduces your waste. By monitoring your liquid foam and film, the bar-coding system provides the right amount of liquid foam for each product every time. Each product receives an individual bar code assigned to identify it. From there, the bar code data will be programmed to match the pack-out requirements of that individual product. With the scan of a bar code, the Foam in place system will dispense the exact amount of liquid foam and film needed every time.

3. Equipment Design

A system created for the operator, our Foam in place systems design is meant to provide user-friendly features. With user-friendly, programmable bag makers, user-friendly hand-held dispenser technology, our Foam in place systems are easy to use for any operator. The ergonomics, advanced software and lightweight chemical pumps of our Foam in place systems all create a machine that is made from intelligent design.

4. Customer Focus

Our Foam in place systems are created to provide top-notch service to our customers. With systems made for the user in mind, we offer quick turn-around that reduces downtime, increases productivity and provides tools and parts included with the equipment lease at no additional cost.

5. The Advantage Program

A customized program tailored to your specific needs, the Advantage Program is an excellent option that requires no up-front capital investment. This program is made to be flexible, so it can adapt to your changing business needs as time progresses. Advantages of the program include: installation, training and on-going support, a lifetime warranty on parts and equipment, ongoing expert consultation for changes in your packaging needs and other exciting benefits. Be sure to ask one of our customer service representatives about the Advantage Program.

Packaging Technology for Smart Business

Foam in place protective packaging has been around for more than 30 years, but never has there been a solution quite like this. Foam in place systems transform mature technology into an intel-ligent, cost-effective approach to foam packaging.

How it Works

Foam in place polyurethane is molded in real-time by combining two liquid foams in a pre-fabricated mold, high-density polyethylene bag or film. The mixture expands rapidly around the product being protected, creating a custom protective shell. Our Foam in place is a time-tested, field-proven packaging alternative designed to help the busiest, high-volume warehouses, distri-bution centers and manufacturing facilities work simpler and smarter. Our systems feature the most cost-effective, time-efficient Foam in place packaging technology in the industry delivering the highest degree of packaging protection across multiple applications, fast.

Pre-Molding Foam Applications

Ensure consistent cushioning for your products with pre-molded foam. You will have custo-mized, engineered, pre-molding that is perfectly fitted to your products for maximum protection. In five quick steps the customized molded foam is ready for your packaging needs. The Smart-MOLD product line features these types of applications for protective packaging.

Foam-in-Bag Applications

The foam-in-bag concept is simple. By choosing the size bag you want from six sizes available, you then dispense liquid foam in the bag. Allow the foam in the bag to mold around the product being packaged, transforming the bag into a "shell" that provides the ultimate protection. The SmartBAGGER foam-in-bag packaging system is ideal for this type of product application.

Foam in place Applications

With six standard bag sizes available, customers simply choose the size they want. Liquid foam is then automatically dispensed inside the bag, transforming into a shell around the product for optimal protection. Both product lines, the SmartSHOT and SmartSHOT Hybrid, are capable of this Foam in place application.

Compare our Products

  SmartMOLD SmartBAGGER SmartSHOT SmartSHOT Hybrid
Application Pre-mold Foam-in-bag Foam in place Foam in place
(machine dememsions)
Pregis will create and build custom molds for product/applications requiring precise and consistent cushion sizes. Height: 65.5" + Stroke

Width: 44.6"

Depth: 39.1"
Hose Hanger Height: 8-12'

Console Height: 5' Nominal varies by install

Heated Hoses: 20'

Feed Hoses: 13'
Stand Dimensions: 24"(W) x 44"(T) x 24" (D)

Standard wicket bag size: 18"(w) x 24"(L)

*Other bag sizes available upon request.
Utility Requirements
- Electrical power
- Receptable type
208 or 230 Volts AC
30 Amp dedicated circuit
50/60 Hz
Plug configuration = L6-30

Foam Supplies

SmartFOAM - A/B Liquid Foam

  55 gallon drums* 275 gallon totes
A-Liquid foam 500 lbs 2,500 lbs
B-Liquid foam 450 lbs 2,300 lbs
Features Clear outer container color allows user to visually see foam consumption.

Inline and barrel pump options available with state-of-the-art brushless motors and controls to run longer. No additional components required.
Clear outer container color allows user to visually see foam consumption.

Inline and barrel pump options available with state-of-the-art brushless motors and controls to run longer. No additional components required.

SLD - Super Low Density Foam

Provides average cushioning and material recovery.
High performance replacement for loose fill, kraft paper, air bags, cellulose wadding or newspaper.

HE - High Efficiency Foam

Provides good, initial cushioning.
Fair protection after multiple drops for medium to heavy products (20-60lb).
Preferred alternative for all flexible protective packaging.

MLD - Moldable Foam

Provides flexible cushioning
Excellent recovery for fragile or heavy (40-120 lbs.) products after multiple drops.
Excellent replacement for all flexible protective packaging.
Pads may be reused.


Excellent recovery for fragile or heavy (50-150 lbs.) products after multiple drops.
Excellent replacement for all flexible protective packaging.
Pads may be reused.


The SmartLUBE is the solution that is used in order to clean and maintain the Foam-In-Place machine parts.

Foam Accessories
We also provide some additional options that will help you further succeed in your packaging agenda. You can choose to mix and match the following foam packaging cushioning.
The programmed bagger system that will create continuous foam chambers. Use the foam chamber packaging as a void fill for product cushioning.
You can create flat cushions with the SmartCUSHION system. The system is automatic and requires no operator. Don't worry about malfunctions because when a jam occurs a built-in sensor will stop the equipment. This system is perfect for void fill on all sides of a package.

Instapak Quick RT Foam Packaging

Instapak Quick RT foam packaging is a packaging alternative providing consistent, custom-fit protective packaging that requires no system or warmer. Instead, the Instapak Quick RT Foam Packaging is activated right out of the box by hand, at room temperature. This foam in place alternative is a quick, easy-to-use expandable foam packaging which virtually eliminates shipping damage.

  • Versatile Packaging: foam packaging protects products of almost any size, shape, and weight
  • Can be used anywhere, anytime
  • Foam cushions provide durable cushioning, blocking, and bracing protection for heavy products
  • Foam in place packaging requiring no equipment or warmers
  • Activated right out of the box by hand, at room temperature
  • Foam bags expand up to 27 times their original size

FIP SmartBagger

The SmartBAGGER is a foam in place packaging system that is ideal for high volume, medium to large applications that require protective packaging and packaging damage prevention . The SmartBAGGER is ideal for protective void fill, blocking and bracing products and cushioning during the shipping and handling process.

Our SmartFOAM, SmartFILM, and SmartLUBE foam in place supplies deliver exceptional advantages that translate into long-term value. Safe, comfortable and intuitive to use, IntelliPack SmartBAGGER maximizes packaging line productivity and efficiency.

FIP SmartSHOT Handheld

The SmartSHOT handheld foam in place system is designed for small, medium and large protective packaging applications that require both packaging protection and packaging damage prevention.

The SmartSHOT protects products with conventional or anti-static SmartFILM available in 36 and 48-inch centerfold and 48-inch flat film. A variety of SmartFOAM A/B chemical densities and SmartLUBE Foam in place supplies deliver exceptional advantages that translate into long-term value.

IPS Packaging has a full line of Protective Packaging systems that will provide your products with packaging safety. Choose your protective packaging from our IntelliPack product line, which includes foam in place, foam in bag and foam in place pre-mold. These are top of the line expanding foam products.

FIP SmartSHOT Hybrid

The IntelliPack SmartSHOT Hybrid is an innovative cross between a handheld foam in place machine and bagger system. An affordable option with the same maximum foam in place packaging protection benefits, SmartSHOT Hybrid comes in multiple foam in place bag and stand dimensions to best tailor to your packaging needs.

IPS Packaging has a full line of Protective Packaging foam in place systems that will provide your products with packaging safety. Choose your protective packaging from our IntelliPack product line, which includes foam in place, foam in bag and foam in place pre-mold. These are top of the line expanding foam products.