November 8, 2021

Popping the Cork on Planet-Friendly Packaging

Biofoam Header Image


In developing and designing new packaging solutions geared to help companies take meaningful action towards product sustainability, the NPD team at IPL Packaging created an eco-friendly and sustainable champagne pack using BioFoam as the chief substrate.

“BioFoam, or stash injection moulded paper foam, is a biopolymer based on industrial starch derived from potatoes or sugar cane and/or bamboo cellulose fibres, produced via an injection molding process,” says LB Odendaal, Head of Design at IPL Packaging.  “By making use of an infinite natural resource, the key features of this packaging material are that it is compostable, paperstream recyclable and 100% biodegradable.”

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“As a patented product, BioFoam is the first foam to have an organic base, with the consequence that it can then be reused,” he states. “In this particular application, we designed the body or ‘shell’ of the pack to be shaped to the bottle and constructed entirely of BioFoam. Interiors feature channels or ribs to assist in keeping the bottle securely in place.”

“Cut-outs in the pack were created in order to reduce reliance on material and also provide a sense of intrigue by enabling the consumer to glimpse the product within,” says Odendaal. “Removable silicone bands around the base and neck of the pack then help to keep it closed, whilst branding is achieved though a subtle debossing technique.”

“We’re working hard to ensure we’re able to provide packaging products with minimal impact on the environment which is why BioFoam, amongst the many other materials we test and trial, offers a perfect solution,” he explains. “BioFoam is durable and suitable for long-term use in virtually all technical and packaging applications, thereby making it perfect in so many ways,” states Odendaal.

Biofoam Cut Out Image 2


BioFoam is a packaging material well suited to both molded parts and cut products. This opens the door to technical products and packaging solutions with an unprecedented freedom of design, owing to its many attractive properties:

  • Lightweight
  • Retains its shape
  • Excellent insulation
  • High shock absorption
  • Hygienic
  • Complete three-dimensional freedom of design
  • Resistant to UV radiation
  • Not hazardous to health

IPL Packaging is a global luxury packaging supplier with offices in the USA, Europe, Mexico, Asia and Africa. Approved manufacturing is available in several Asian countries, as well as sites in Eastern Europe. We create bespoke, tailored and exclusive packaging for any premium or luxury brand and lead the entire process, from conceptualisation and design to production and delivery.

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