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custom manufacturePlastic foams are endlessly versatile; they can be moulded into almost any shape and they are light and strong.

At Styropack, we specialise in collaborating with customers on individually designed items that are tailored to meet your requirements.

If it is protective packaging you want, tell us what job you want done and the Styropack design team will make it happen.

We can guide you through the material options, looking at the characteristics of each material and the difference that density levels will make to the protection levels.

If you seek re-usable packaging, we can show you examples of other reusable applications and help you to make the right choices for the protection of your product.

But, Styropack does not just make protective packaging; our highly skilled designers and workforce have moulded a range of speciality items including:

  • safety helmets
  • child car seats
  • air conditioning units
  • boiler casing
  • bath panels
  • automotive components
  • lighting

We welcome a challenge, our enthusiastic and committed team has the experience and the skills to help you develop the moulded foam product that develop the product and match that to a material that delivers exactly the properties you need.

The Custom Manufacture Process

The process of developing a product from scratch can be as quick as six weeks, depending on how long we spend on each stage.

Once we have your brief, using the latest CAD (computer aided design) software, we can quickly produce 3d designs that can be viewed and tested before a prototype is created.

Once you are happy with the 3D design, the next stage is to prototype it. With our CNC (computer numerically controlled) cutting equipment, we can produce prototypes with total accuracy.

The prototype allows you to handle your product for the first time and you can test your product or packaging and make sure it is fit for purpose.

For protective packaging, we can perform tests on the packaged item to see the packaging provides the required level of protection. That way we can ensure your products will arrive at their destination undamaged – however robust the handling.

At this stage of the custom manufacture process, you can make the small, vital adjustments that are only possible with a prototype to view and test.

Once you are entirely happy with the prototype, we will order your tool for manufacturing your product in volume. Our design team will manage this process for you, getting competitive quotes and ensuring that the tool is correctly made before production starts.


We have three manufacturing sites; each one is equipped with the latest, energy efficiency machines, we run flexible shifts and can accommodate the most demanding of manufacturing programmes to meet your deadlines.

Our logistics team will work closely with you to set up the service levels and delivery agreement that you need.