Overview on Foam Forming Cellulose Materials for Cushioning Packaging Applications

Wet foam can be used as a carrier in the manufacturing of lightweight materials based on natural and man-made fibers and specific additives. Using a foam forming method and cellulose fibers, it is possible to produce the porous materials with large area of end-using such as protective and cushioning packaging, filtering, hydroponic, thermal and sound absorption insulation, or other building materials. In comparison with the water-forming used for conventional paper products, foam-forming method provides many advantages. In particular, since fibers inside the foam are mostly trapped between the foam bubbles, the formed materials have an excellent homogeneity. This allows for using long fibers and a high consistency in head box without significant fiber flocking. As result, important savings in water and energy consumptions for dewatering and drying of the foam formed materials are obtained. In cushioning packaging, foam-formed cellulose materials have their specific advantages comparing to other biodegradable packaging (corrugated board, molded pulp) and can be a sustainable alternative to existing synthetic foams (i.e., expanded polystyrene or polyurethane foams). This review discusses the technical parameters to be controlled during foam forming of cellulose materials to ensure their performances as cushioning and protective packaging. The focus was on the identification of practical solutions to compensate the strength decreasing caused by reduced density and low resistance to water of foam formed cellulose materials.