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Frequently Asked Questions

Yes, we do. We know many products we sell are hard to find or expensive at retail prices, so we will try to help you out with whatever you need. Always best to call 24/7.

We only offer wholesale pricing which does not differentiate between customer types, only by volume.

There are two ways to buy.

1 - You may come into our location in Clearwater, Florida

1 - We can ship to you.

If you live in the area, we do sell foam leftovers from jobs at discounted prices. Call for availability.

Our minimum size order depends on whether you are picking up locally or we are shipping to you.

If you are coming in here, then we have a minimum of $50.

If we are shipping you, then it really depends on what you are ordering and where you are located. It is best to call us and we can let you know if it makes sense for you to buy and ship your order.

The best type of foam to use for packaging depends on several factors, fragility, size and weight of the product being packaged, the level of protection required, will it be reused, aesthetics, difficulty for customer to remove, temperature considerations, environmental considerations, and budget constraints. Here are some common types of foam used for packaging and their characteristics:

We only offer wholesale pricing which does not differentiate between customer types, only by volume.

Expanded Polystyrene (EPS) Foam

Advantages

Lightweight and cost-effective.
Excellent shock absorption and cushioning properties.
Insulating properties help maintain temperature stability.
Can be recycled in some areas.

Considerations

Less environmentally friendly compared to some other options.
May create static electricity during handling.

Polyethylene (PE) Foam

Advantages

Soft and flexible, providing good cushioning and protection.
Resistant to moisture and chemicals.
Can be recycled in some areas.

Considerations

May be more expensive than EPS foam.
Limited options for recycling compared to other materials.

Polyurethane (PU) Foam

Advantages

Soft and resilient, offering excellent shock absorption.
Can be customized for specific applications.
Resistant to compression set and deformation.

Considerations

Typically more expensive than EPS or PE foam.
May off-gas volatile organic compounds (VOCs) during manufacturing.

Cross-Linked Polyethylene (XLPE) Foam

Advantages

Higher density and strength compared to standard PE foam.
Resistant to water, chemicals, and UV radiation.
Excellent shock absorption and cushioning properties.

Considerations

Higher cost compared to other foam options.
Limited options for recycling.

Molded EPS coolers are made by expanding EPS beads into a mold. The coolers are made out of one piece and have a separate lid.

Insulated EPS box liners are usually 6 separate panels of foam that fit into each side of your box.

Insulated box liners are also called thermal box liners, insulated box inserts, insulated box panels, cooler box liners, and Styrofoam box liners.

Both molded coolers and box liners are both used for thermal insulation and protection during shipping and storage, and they both have their advantages:

ADVANTAGES OF INSULATED BOX LINERS:

Lower in cost

box liners are less in cost than molded coolers

You pick your own box

since the cooler can be made to any size box, you can use whatever box you want including your existing boxes, custom printed boxes, the right strength and size, stock boxes, etc.

Lower in box costs

because molded coolers will only fit their custom size boxes, you are limited and pay more because of it.

Lower shipping costs

because you can strategically pick the exact size box you need, you don’t waste space which can save a lot on overnight or two day shipments. And a molded cooler has rounded corners and a tapered shape to be able to come out of the mold, which means you can’t fit in as much.

Thickness is adjustable depending on season

You can have a thicker cooler in the summer and a thinner cooler in the winter, potentially saving you shipping costs!

Less storage space

Insulated shipping liners are flat pieces when shipped or stored. Molded coolers are fully assembled so they take up more space.

Can be made from recycled foam

Thermal box liners can be made from recycled foam.

ADVANTAGES OF MOLDED COOLERS

Molded coolers have higher R-value

Molded coolers have about 5%-8% increased R-value than insulated box liners if the same thickness.

Molded coolers are assembled

This saves labor time as only the lid has to be put on.

Molded Expanded Polystyrene (EPS) foam packaging refers to packaging solutions made from expanded polystyrene foam, often called Styrofoam, that has been molded into specific shapes to protect and cushion products during shipping, handling, and storage.

A mold must be made which can be quite expensive, in the many $1000’s, and can increase lead times significantly. Also, to modify a mold in the future, can be quite expensive.

The MOQ (minimum order quantity) for molded foam is usually enough product to fill approximately half of a semitruck.

IPS Foam specializes in making molded EPS foam parts, but without the molding! This means you save $1000’s on the mold, your MOQ is quite small, and you can make changes much easier than if you have a mold. Call us for more details.

Recycled foam means a portion of the material to make the foam was from post-industrial waste material of the same type. When foam is being cut into shapes, for example, the leftover foam gets re-grinded and then used for the next batch of foam, hence the other name for recycled foam which is regrind foam. Virgin foam is made from newly manufactured raw materials with no reused material.

Both expanded polystyrene EPS foam, commonly called Styrofoam, and polyethylene PE foam are sold as both recycled and virgin products. Recycled foam is less in price for both types of foam, but not in a significant amount.

There is a minor difference between recycled and virgin EPS foam. The recycled foam is not quite as smooth as when you cut the foam with a hot wire, and the recycled foam is only available in the one pound per cubit foot density. For packaging, the difference can be insignificant. The advantage to both the environment, and for your customers to know you are eco-conscience, could make recycled foam a logical choice.

Virgin EPS foam, however is better for when you must cut smoother and have tighter specs. If you are carving a sculpture, or need foam that is denser than one pound per cubic foot, you must get virgin.

With PE foam, the recycled foam is black, instead of white, which most people prefer, and the characteristics are basically the same, and the price is considerably less, so the recycled PE is much more popular. About 95% of the PE we sell is recycled, for reference purposes.

Foam recycling depends on the type of foam material. Some types of foam are recyclable, while others may not be widely accepted by recycling facilities due to technological limitations or economic factors. Here's an overview of the recyclability of common types of foam:

Expanded Polystyrene (EPS) Foam

EPS foam, often known as Styrofoam, is recyclable, but recycling options may vary depending on location. Many recycling facilities accept clean EPS foam packaging materials, such as foam blocks, packaging peanuts, and foam cups, for recycling. However, it's essential to check with local recycling programs or facilities to confirm whether they accept EPS foam and if any specific preparation or sorting is required.

Polyethylene (PE) Foam

PE foam, also known as polyfoam or foam sheeting, is recyclable but may not be as widely accepted for recycling as EPS foam. Some recycling facilities may accept PE foam for recycling, while others may not have the necessary equipment or processes to recycle it efficiently. It's advisable to check with local recycling programs or facilities to determine their policies regarding PE foam recycling.

Polyurethane (PU) Foam

PU foam, commonly used in furniture cushions, mattresses, and insulation, is less commonly recycled due to its composition and processing requirements. While there are some efforts to recycle PU foam, such as mechanical recycling or chemical recycling processes, these methods may be limited in availability and effectiveness. As a result, PU foam recycling options may be more limited compared to EPS or PE foam.

Other Specialty Foams

because you can strategically pick the exact size box you need, you don’t waste space which can save a lot on overnight or two day shipments. And a molded cooler has rounded corners and a tapered shape to be able to come out of the mold, which means you can’t fit in as much.

What is important to note is the impact of the foam on the environment when made, transported and used.

What is important to consider when evaluating environmental impacts of any material is to look at the entire life cycle including production, transportation, use, benefit and disposal. Of all the foams we sell, EPS foam has the least impact.

The manufacture of EPS foam is a low-pollution process. Steam is used and the water is reused many times.

Due to its lightness and minimal distance transported, the environmental impacts from transportation are minimal.

EPS is mostly air and is 100% recyclable and is used in coat hangers, garden furniture, etc.

When EPS is used for insulation in a building, then of course EPS benefits the environment substantially.

Yes, you may bring your EPS foam here as long as it is clean, and the drive does not nullify the benefit of bringing your foam here. We always cringe when someone drives 20 miles in their combustible engineered to bring us a few pieces of foam. Make sure to combine the drive. ALL FOAM MUST BE CLEAN with not tape, glue, etc.

Most of the time, people are looking for expanded polystyrene foam, but mistakenly refer To it as Styrofoam as this is the generic trademark, even though the materials are different.

"Styrofoam" is actually a trademarked term owned by The Dow Chemical Company, which is used to refer to a specific type of extruded polystyrene foam insulation, usually blue in color.

On the other hand, EPS foam, or Expanded Polystyrene foam, is a generic term used to describe a broader category of foam made from expanded polystyrene beads.

EPS foam is typically manufactured using a steam-driven process where polystyrene beads are expanded and fused together to form blocks or shapes.

Styrofoam, on the other hand, is made through a different manufacturing process called extrusion,

Cutting Styrofoam (EPS foam) can be messy unless it is done by a hot wire or hot knife, both can be purchased online.

Depending on what you are buying and doing with the foam, we can cut the foam for you here much quicker, cleaner, and more economical than you can do it yourself. Just tell us what you are doing and we’ll see if we can help.

But if you are only making a few cuts and want to do it yourself, then here are some options. method you choose, be sure to work in a well-ventilated area to minimize exposure to Styrofoam dust and fumes. Additionally, wear appropriate safety gear, such as gloves and eye protection, especially when using sharp tools or power equipment and follow all safety guidelines in the manufacturer’s manual.

Do not cut foam where pieces of the foam will go into the environment. Whichever

Utility Knife or Craft Knife

Use a sharp utility knife or craft knife with a retractable blade.
Mark the cutting line on the Styrofoam using a ruler and pencil.
Hold the Styrofoam firmly in place and carefully cut along the marked line using the knife.
For thicker Styrofoam or more precise cuts, make multiple shallow passes with the knife until you cut through the foam completely, or you can partially cut through the foam and then snap the piece where the cut it.

Hot Wire Cutter

A hot wire cutter, specifically designed for cutting foam, can provide precise and clean cuts.
Mark the cutting line on the Styrofoam.
Turn on the hot wire cutter and wait for it to heat up
Hold the Styrofoam firmly in place and carefully guide the hot wire cutter along the marked line to cut through the foam. The heat from the wire will melt through the foam, leaving a smooth edge..

Table Saw

A table saw can also be effective for cutting Styrofoam, but beware of the dust.
Position the table saw and yourself properly
Adjust the blade height
Use a push stick or push block
Mark the cutting line on the Styrofoam.
Use a rip fence or miter gauge
Use the blade guard
Maintain control while cutting

Serrated Knife

A serrated knife, such as a bread knife, can also be used to cut through Styrofoam.
Hold the Styrofoam firmly in place and carefully saw through it using the serrated knife.
This method may not provide as clean or precise cuts as some other methods but can be effective for basic cutting tasks.

Band Saw or Scroll Saw

If you have access to woodworking tools, such as a band saw or scroll saw, they can be used to cut Styrofoam.
Mark the cutting line on the Styrofoam.
Set up the band saw or scroll saw with a fine-toothed blade suitable for cutting foam.
Hold the Styrofoam firmly in place and carefully guide it through the saw along the marked line to cut through the foam.

It depends on the type of foam you have.

If you have expandable polystyrene (EPS) foam, also commonly called Styrofoam, you must be careful the glue has no solvents, which is most types of glue. If you’re not sure, test the adhesive first.

Expandable gap filler glue, such as The Great Stuff, available at Home Depot or Lowes, works excellent and adheres to most any surface. The spray foam can be used to glue foam to each other, to glue architectural foam to walls, etc. After spraying the expanding foam, you may want to wait around one minute or slightly more until it is sticky.

You can use a white glue (PVA glue), like Elmers Glue, but this has to be held under pressure while it dries for 30+ minutes.

You can use Liquid Nail, but test it first as some types of liquid nails can dissolve the foam.

There are adhesive sprays that are specific for foams made by 3M and other companies.

Certain hot melt glues work also. These are applied industrially with spray guns or hot roller machines.

If you are gluing polyethylene (PE) foam and cross-linked (XLPE) foam, you are better to heat bond the foam together using a heat gun. This takes practice as you must be EXTREMELY quick as the foam cools instantly. You can only do a small area at a time and must immediately join the two pieces of foam together while they are being heated.

At IPS Foam, we have commercial equipment that automatically heat bonds foam together.

You can adhesives to bond PE and XLPE Foam, using a flexible PSA (pressure sensitive adhesive). This is available commercially.

If you are bonding polyurethane PU foam together, you would need a special PSA adhesive also.

There are spray adhesives designed for foam that do work, but you will need to test as often they do not bond very well.

Foam by itself is too soft for many applications such as architectural, monuments, signs, certain props, statues, boulders, and fountains.

There are multiple types of coatings for foam for both exterior and interior applications. The determining factor is how hard do you want the foam to be, how much time and money do you want to spend, and what do you want it to look like.

Coatings cannot have any solvents in them, or they will dissolve certain foams like expanded polystyrene (Styrofoam) unless there is a barrier constructed on the foam.

It should be noted that the density of the expanded polystyrene foam can affect the durability of the foam along with the coating. EPS foam generally is sold in 1, 1.5 and 2 pound densities per cubic foot. The higher the density, the stronger the foam and often the smoother the coating will go on the foam, or the less coats you will need to get the desired smoothness.

Polyurethane Coatings / Polyurea Coatings

Polyurethane coatings are versatile and can be formulated to provide different levels of hardness and flexibility. They can be applied as a spray-on coating and cure rapidly, forming a tough, seamless membrane over the EPS foam surface. They offer good durability and weather resistance, making them suitable for outdoor applications.

Cementitious Coatings

Cementitious coatings are composed of cement, sand, and polymers. They are applied as a slurry or mortar and can provide a durable, fire-resistant finish for EPS foam.

Limestone Acrylic

Seemingly indestructible, our limestone acrylic aggregate can be hand applied, sprayed and extruded, leaving a thick covering of stone like material that has such a beautiful natural stone look that many people never coat it making it a maintenance free product that lasts indefinitely.

Acrylic Latex Paint Coatings

Acrylic coatings are water-based and environmentally friendly. They can be applied as a brush-on or spray-on coating and provide a hard, smooth finish. Acrylic coatings are often used for artistic or decorative applications. Latex paint, even if multiple coats, will not add and significant hardness to the foam, however.

Elastomeric Roof Coating

Elastomeric roof coatings are water based so they will not damage EPS foam. It can be brushed on, just like acrylic paint, but it is much thicker. There are different types of elastomeric coatings, so you may have to do some experimenting. The thicker the coating, the better. Elastomeric coatings, while thicker and a bid harder than paint, is still not a hard finish.

Fiberglass Coatings

Fiberglass coatings consist of a layer of fiberglass mat or fabric embedded in a resin matrix. They offer high strength and impact resistance and can be applied as a laminate over EPS foam surfaces. Polyester resin reacts with EPS foam, so a barrier will need to be applied such as wrapping foil or painting the foam.

Epoxy Coatings

Epoxy coatings offer strong adhesion to EPS foam and provide a hard, glossy finish. They are often used for decorative applications or where a high level of chemical and abrasion resistance is required. They are more expensive than polyester fiberglass, but they do not require applying a barrier on the foam as they will not dissolve the foam.

Silicone Coatings

Silicone coatings provide a flexible, waterproof barrier over EPS foam surfaces. They are often used for applications where movement or vibration is expected, such as in building construction or marine applications.

Here are some Do-It-Yourself coating products for EPS foam

Foam is used for architectural elements for several reasons, including its versatility, cost-effectiveness, ease of installation, and aesthetic appeal. Here are some of the key reasons why foam is commonly chosen for architectural applications:

Lightweight

Foam is lightweight compared to traditional building materials such as wood, metal, or concrete. This makes it easier to handle, transport, and install, reducing labor costs and construction time.

Versatility

Foam can be easily molded, shaped, and carved into virtually any design or pattern, allowing architects and designers to create intricate and customized architectural elements. It can replicate the look of more expensive materials such as stone, wood, or metal, offering a wide range of design possibilities.

Cost-Effective

Foam is generally less expensive than many other building materials, making it a cost-effective option for architectural applications. It can help reduce overall project costs while still achieving the desired aesthetic and design goals.

Ease of Installation

Foam architectural elements are often prefabricated off-site, allowing for quick and straightforward installation on-site. This reduces construction time and disruption, leading to faster project completion and reduced labor costs.

Insulating Properties

Some foam materials, such as Expanded Polystyrene (EPS) or Polyurethane (PU) foam, offer thermal insulation properties, helping to improve energy efficiency and indoor comfort in buildings.

Durability and Weather Resistance

Foam materials can be coated or treated to enhance their durability and resistance to weather, moisture, UV radiation, and pests. Properly protected foam architectural elements can withstand outdoor exposure and maintain their appearance for many years.

Sound Absorption

Foam materials can provide acoustic insulation and sound absorption properties, helping to reduce noise transmission and improve the acoustics of interior spaces.

Customization and Replication

Foam can be easily customized to match specific design requirements or replicate historical architectural details. It allows for the creation of unique and visually striking architectural elements that enhance the overall aesthetic appeal of buildings.

Overall, foam offers a combination of versatility, affordability, ease of installation, and aesthetic appeal that makes it a popular choice for a wide range of architectural applications, including cornices, moldings, columns, trim, decorative accents, and more. Its ability to mimic the appearance of traditional building materials while offering additional benefits such as lightweight construction and design flexibility makes it a preferred option for architects, designers, and builders.

Soundproofing and sound-absorbing are two different techniques used to manage sound in indoor spaces, each serving distinct purposes:

Soundproofing

Purpose

Soundproofing aims to prevent the transmission of sound from one space to another or reduce the amount of external noise entering a room. It focuses on blocking or isolating sound waves to maintain privacy and minimize disturbance.

Methods

Adding mass: Increasing the density of walls, floors, and ceilings using materials such as heavy drywall, concrete, or mass-loaded vinyl to block sound transmission.
Decoupling: Installing resilient channels, isolation clips, or soundproofing mats to create separation between surfaces and prevent sound vibrations from transferring.
Sealing: Closing gaps, cracks, and openings in walls, windows, and doors to minimize sound leakage.
Adding barriers: Erecting sound barriers such as soundproof curtains, acoustic panels, or double-glazed windows to reduce external noise.

Applications

Soundproofing is commonly used in recording studios, home theaters, bedrooms, offices, and commercial spaces to create quiet environments and reduce noise disturbances.

Sound Absorption

Purpose

Sound absorption aims to reduce the reverberation or echo within a room by absorbing sound waves, improving acoustics, and enhancing speech intelligibility. It focuses on controlling the reflection of sound within a space.

Methods

Installing acoustic panels: Mounting sound-absorbing panels or tiles made from materials such as fiberglass, foam, or fabric on walls, ceilings, or partitions to absorb sound reflections.
Using acoustic ceiling tiles: Installing perforated or textured ceiling tiles with sound-absorbing backing to reduce sound reverberation.
Placing acoustic drapes or curtains: Hanging heavy, dense curtains or drapes made from sound-absorbing materials to reduce sound reflections and dampen noise.
Adding acoustic furniture: Incorporating upholstered furniture, carpets, rugs, or acoustic partitions to absorb sound and reduce reverberation.

Applications

Sound absorption is commonly used in auditoriums, conference rooms, classrooms, restaurants, theaters, and recording studios to improve sound quality, minimize echoes, and create a more comfortable listening environment.

In summary, soundproofing focuses on blocking or isolating sound to prevent its transmission between spaces, while sound absorption focuses on reducing sound reflections within a room to improve acoustics and minimize reverberation. Both techniques play essential roles in creating comfortable and functional indoor environments with appropriate levels of sound control.

We sell Polyethylene PE Foam sheets ½” to 6” thick from 1.7 to 6 lbs. densities in black and white.

We sell Extruded Polyethylene EPE Foam sheets from 1.2 to 6 lbs. densities in black and white.

We sell Expanded Polystyrene EPS (Styrofoam) foam sheets from 1 to 3 lb. densities in white.

We sell Polyurethane PU Foam sheets of all densities and firmness (ratings on the Indentation Force Deflection (IFD) or Indentation Load Deflection (ILD) scale) in different colors.

We sell sheets of cross-linked XLPE Foam sheets most commonly in 2 and 4 lb. densities in different colors.

We sell sheets of Convoluted (Eggcrate) Polyurethane Foam sheets in different densities and different peak heights, thicknesses, and colors.

We sell sheets of Shadow (Kaizen or Tool) Foam sheets in different colors and thicknesses.

We sell Reticulated Foam sheets in different Pores Per Inch" (PPI).

We sell EVA Foam sheets in a variety of thicknesses and types

The most common foam for sculpturing is Expanded Polystyrene (EPS) Foam that is virgin foam, not recycled.

The higher the density the foam, the higher harder the foam is and the finer detail you can cut into the foam. The most common density for sculpturing foam would be 1.5 lb. density, followed by 1 lb., and then 2 lb. EPS foam.

You can also carve Extruded Polystyrene XPS Foam, but it is normally only available in 2” thick sheets, which is too thin for three-dimensional sculpturing.

Shredded urethane foam is a type of cushioning material made from pieces of polyurethane foam that have been cut or torn into small, irregularly shaped fragments. This shredded foam is often used as filling for pillows, cushions, bean bags, pet beds, and various upholstery applications because it can conform to different shapes and provides good support and comfort.

Geofoam is specially engineered expanded polystyrene (EPS) foam. It is used in construction as a lightweight fill material to reduce loads on underlying soil or structures. Geofoam is designed to provide stability, reduce settlement, and improve overall performance in various applications such as road construction, embankments, and slope stabilization.

Concrete foam-block outs are placed within concrete forms to create voids or openings for pipes, electrical conduits, or other utilities. Concrete is poured around or over the EPS foam. After the concrete hardens, the foam can be removed or dissolved, therefore, exposing a void, or “block out”, in the concrete.

Other names used for foam block outs include void forms, foam inserts, foam void forms, polystyrene block outs, concrete voids, formwork block outs, core forms, and Styrofoam block outs.

If you are buying anything custom cut, fabricated, or ordered, we do not allow returns. We strive ourselves on making sure you get what you want. That is why we do not have ecommerce on our site. We would rather talk first to our customers and make sure they know what they need or are getting. For production runs, we can do samples first.

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IPS Foam LLC

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  • 1611 N Hercules Ave Clearwater, Florida 33765
  • CALL 7 DAYS A WEEK!
  • 727-447-0085
  • Mon-Fri 8:00-5:00,
    Weekends and After Hours,
    By Appointment

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