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Uniform foam density is easy to quote and easy to overpay for. A tray that cradles castings and painted sensors at the same bead density either overprotects the castings or underprotects the sensors, and either way the programme pays: in foam cost, in damage claims, or in both. Our EPP liners grade the density to what each region of the tray actually carries.
Three densities, one tray
Steam moulding lets us change bead density by zone inside a single moulding. Guide walls and stacking surfaces run at 30 kg/m3, general cradle areas at 45 kg/m3, and contact zones for painted faces, glass or sensors at 60 kg/m3. The liner arrives as one part number with the protection already allocated to the right places.
Where the money actually goes
For a mixed tray, grading typically trims fifteen to twenty-five percent off foam weight compared with a uniform 60 kg/m3 liner, and weight is the main driver of bead cost. The dense zones stay exactly where damage has happened on your lines, because the layout starts from your claim history, not from a default fill.
Standard graded platforms
VM 1210: 1200 x 1000 mm tray set, three density zones, payload 80 kg, for mixed casting and machined families.
VM 865: 860 x 650 mm tray set, two density zones, payload 40 kg, for kitted subassemblies.
VM 604: 600 x 400 mm tray set, graded contact pads, payload 20 kg, for painted and plated parts.
VM-S: sensor and glass cradle inserts cut as separate parts for tray designs that change often.
Proof before tooling
Prototype liners are CNC-cut from CAD at graded densities for a fit and drop trial. We log which zones take contact, adjust the density map, and only then cut the steam mould, so the production liner inherits a layout that has already survived your handling.
One part number, cleaner stock
Because grading lives inside one moulding, stores stock a single liner per tray instead of separate blocks and pads. Replacements are ordered by tray number, and audits show one material certificate covering all zones.
Send us the tray, the part mix and two years of damage records, and we will return a graded density proposal with a weight and cost comparison against your current liner.
