Recycled Foam and Sustainable Packaging

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Recycled polyethylene and polyurethane foam products

We're working alongside our manufacturing partners and customers for a better tomorrow when it comes to foam production and recycling.

As so many plastic products end up in landfills, we're producing more and more foam products that are redeveloped using recycled foam materials. That means the foam is reused multiple times throughout its life cycle to fully benefit its protective properties.

Cost-effective, sustainable and with a high resistance to wear and tear, our durable recycled and reconstituted foams are made to last, making Zouch a 'one stop' source for environmentally friendly products and therefore supporting a reduced carbon footprint.

They can be cut to size and are available in a range of different densities and colours, offering various options to businesses seeking more sustainable opportunities for their projects.


Take a closer look at the Zouch range on our product pages or get in touch with our expert support team for free samples and project advice.

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Recycled ZOUCH eFoam NXL range

A non-cross-linked closed-cell and non-toxic foam, which is flexible & a recyclable polyethylene foam. It's known for its outstanding stability and recovery with unparalleled cushioning protection against impact. Anti-static and/or flame-retardant, sound-absorbing, low-abrasion, and has a minimum of 65-100% recycled resin content.

Applications: various packaging options from delicate items to furnishing, electronic protection and heavy-duty dunnage.

Recycled foam

Recycled ZOUCH eFoam 3R

Our recycled cross-linked foam is an environmentally friendly solution and lightweight substitute for outdoor surfaces. Made from 100% recycled post-industrial cross-linked polyethylene foam, it's ideal for energy and shock absorption, offers excellent insulation, provides drainage against wet weather conditions and is durable and hard-wearing.

Applications: excellent for playgrounds and play area surfaces, rooftop gardens, patios and balconies and sports and leisure facilities.

Cross linked closed cell tile 2

Reconstituted Foam ZOUCHrecon 6/8/10/12

Our reconstituted polyurethane foam (also known as chip foam and recon foam) is a practical, low-cost packaging foam used to protect products during transit and whilst being kept in storage. It's made from offcuts of polyurethane foam, which is tightly compressed and creates a recycled, multi-coloured foam material. Structurally stable, lightweight, insulating, sound-absorbent, hypoallergenic and durable, recon foam has many great benefits.

Applications: used for protective packaging, noise control in fans & blowers, gym mats, church kneeling mats, and cushioning in furnishings such as sofas, caravans, mattresses, bar stools, chairs and more.

Reconstituted foam blocks

Recyclable ZOUCH eFoam R2/R/R4

This low-abrasion, fine-cell and low-density polyethylene foam is 100% recyclable, odourless and non-cross-linked. Its outstanding performance and soft-touch offer excellent cushioning protection against impact, excellent surface protection, damage reduction during transit, and a pleasing aesthetic appeal for display packaging.

Applications: speciality packaging, case inserts, cushioned packaging, sports mats and presentation packs.

Recycable foam

Eco-friendly & Biodegradable Foam Packaging

ZOUCH ecoCell is a biodegradable foam that is an environmentally sustainable, 100% compostable, non-toxic packaging foam.

It is a unique, starch-based material with exceptional cushioning and thermal insulating properties while protecting our planet.

Manufactured from corn starch, ZOUCH ecoCell is the most flexible and convenient packaging material for clean disposal – going further than just recycling.

Biodegradable foam packaging

Typical applications for recycled foam

  • Play areas and playgrounds
  • Protective packaging
  • Cushioning for furnishings
  • Case inserts
  • Sports & gym mats
  • Rooftop garden flooring
  • Electronic protection
  • Protection for heavy-duty dunnage
  • Mattresses
  • Speciality packaging
  • Presentation packs
  • Sport facility flooring
  • Church pews & kneeling mats

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A complete, customised service

From the first call to the finished product, we’re with you every step of the way. We offer technical support and advice on the best foam products for your specific application and assembly process.

We can also provide bespoke product development, on-site support and samples, making the whole design, purchasing and implementation process streamlined and stress free.