Reflex cushioning
A cost-effective and more sustainable alternative to foam for shock sensitive items.
Reduce the risk of damage
Reflex cushioning is effective in absorbing mechanical shock while using less material than traditional PE, EPE, or EPP foam. It provides superior and efficient product protection even after frequent reuse.
Reduce shipping, storage, and handling costs
Reflex cushions allow for up to 85% reduction in shipping, storage, and handling volume, leading to increased assembly line efficiency and lower freight expenses particularly in return flows.
Reduce CO2 & plastic waste
Reflex cushioning lowers CO2 emissions and plastic waste by using up to 100% recycled HDPE that is fully recyclable. Thanks to its high nesting ability, this reusable solution can be collected and returned efficiently at low fuel consumption.
Recycled thermoformed cushioning solutions
Nefab Reflex cushioning solutions
Reflex cushions are customized protective packaging solutions made from thermoformed high-density polyethylene (HDPE) with highly recycled content.
Customized protection
Featuring unique geometries, Reflex cushions provide superior shock absorption compared to traditional foam (closed cell fabricated and molded foam such as PE, EPE, and EPP). They are specifically designed to offer optimal protection for each individual product, resist environmental stresses, and maintain consistent performance. Our experienced engineers, dedication to quality control, and advanced manufacturing ensure reliable products that are validated by ISTA-certified lab tests.
Nesting ability
The cushions are highly nestable, allowing multiple cushions to stack efficiently. This saves up to 85% of space compared to foam.
Complete solutions
Reflex cushioning is usually part of a complete packaging solution.
Replacing foam: Applications of Reflex cushioning
Recycled cushioning alternative to PE foam
Reflex cushioning is ideal for companies looking to replace foam for packing and shipping high-value, shock-sensitive products typically weighing between ½ kg and 50 kg. Unlike some foams, thermoformed cushions are non-particulating, making them ideal for cleanroom environments and datacenters. Reflex cushioning can be adapted to various applications across multiple industries, such as data infrastructure, semiconductor, healthcare and energy equipment.
Cushioning for 2U rack mount servers
Cushioning for hard disc drives
Cushioning for line cards
Cushioning for AEDs
Cushioning for wafer cassettes
Cushioning for 4G/5G remote radio heads
Reference cases
Healthcare: Cushioning for an infusion pump
Nefab partnered with a global healthcare company to make infusion pump packaging more sustainable. Replacing bulky PE foam with Reflex HDPE cushioning cut CO₂ emissions by 62% and reduced total costs by 30%.
Datacom: Cushioning for data infrastructure
A leading data infrastructure company partnered with Nefab to replace PE foam with HDPE thermoformed Reflex cushioning. This led to a 22% cut in CO₂ emissions and a 6% drop in packaging costs, proving cushioning solutions can be sustainable and cost-effective.
Telecom: Cushioning for universal base transceivers
A global telecommunications leader significantly optimized its packaging by switching from PE foam to Reflex cushioning for their universal base transceivers. This change to HDPE end cap cushions led to a 47% global reduction in CO₂ emissions and a 43% decrease in total costs.
Benefits of Reflex cushioning
Reduced use of virgin plastic
Reflex cushioning significantly reduces the use of virgin plastics compared to traditional foam cushioning. Its advanced, thermoformed design requires less material overall compared to equivalent foam applications. In addition, Reflex cushioning is made with up to 100% recycled content, utilizing globally available recycled HDPE.
Reusability
Reflex cushioning is designed for reusability, thanks to their long-lasting cushioning performance and nestable structure. Unlike foam, which occupies up to seven times more space, Reflex cushioning can be efficiently collected, returned and reused, reducing waste and resource use over multiple cycles.
Recycling
HDPE is the second most recycled plastic in the world after PET and can be recycled continuously. This means that Reflex cushioning can be recycled in municipal recycling streams, unlike foam cushions. Moreover, where possible Nefab offers buy-back programs for used Reflex cushioning. Once the cushioning has fulfilled its lifecycle, we collect and recycle the materials to reuse them as raw material to produce recycled thermoformed packaging.
Circularity: Recycled content, reuse and recycling
Reflex cushioning leverages circular concepts to minimize its environmental footprint.
Nestability reduces cost
Unlike foam, Reflex cushioning is highly nestable. This means that the cushioning can be stacked efficiently when not in use. Compared to foam, this nesting ability saves up to 85% of space.
This substantial reduction in volume lowers transport and storage costs, both in inbound supply chains and in return logistics. In addition, the reduced handling volume can significantly increase assembly line efficiency.
Engineered for maximum protection by the market leaders
Reflex cushioning is the leading thermoformed cushioning solution. Owing to over 20 years of expertise in designing, testing, material extrusion, and thermoforming, our Reflex cushioning is highly protective and can outperform traditional foam. Our experienced engineering team ensures that each cushion meets rigorous testing standards. Our efficient design process allows us to deliver high-quality solutions swiftly, ensuring that our customers receive the best service promptly.
Variations of Reflex cushioning
2-piece endcap cushions
4-piece edge rail cushions
Folding corner cushions
Pallet cushions
Multi-pack cushions
Cushion with clamshell
2-piece tray cushions
Modular cushion systems
ESD cushions
How does it work?
Developing plastic packaging solutions: From packaging requirement to solution
- Design and engineering: Based on customer needs, our engineers develop custom concepts designed for optimal manufacturing methods and materials while considering the entire packaging flow.
- Samples and prototypes: Nefab quickly and cost-effectively produces samples and prototypes using various methods including 3D printers, thermoforming and urethane capabilities.
- Testing: In our certified ISTA labs, samples undergo rigorous testing.
- Tooling: Nefab has in-house tool and mold workshops worldwide, along with a partner network, to efficiently create tooling.
- Manufacturing: With our wide variety of manufacturing processes, we produce custom packaging solutions tailored to your needs.
- Logistics services: Nefab provides added logistics services, including assembly work like adding labels, holders, inserts, and tracking devices. Pooling services ensure returnable packaging is repaired, cleaned, and delivered when needed.
- Circular support program: Nefab provides global expertise to uncover reusability opportunities in supply chains and maximize recycling benefits. We can also implement take-back programs with customers, collecting used packaging for recycling at the end of its life.
Benefits of Nefab packaging solutions
Nefab saves environmental and financial resources by optimizing supply chains. We do so by innovating together with our customers to create smarter packaging and logistics solutions while always respecting people and ethical standards.
Complete solutions
We provide complete packaging and logistics solutions that reduce total cost and environmental impact throughout the supply chain.
Engineering expertise
With over 250 engineers in 30 locations globally, we collaborate closely with customers to design, prototype, test, and deliver tailored packaging solutions.
Sustainability focus
Nefab's solutions reduce carbon footprints by 31%, on average, reflecting our commitment to sustainability within our operations and offerings.
Global footprint
With 75 years of experience and a presence in over 38 countries, we deliver global solutions with local support.
Get in touch
Contact your local packaging expert
Looking for cushioning alternatives to foam? Reach out to us today! Our team of experts in more than 38 countries is ready to collaborate, innovate, and deliver solutions tailored to your unique challenges. Contact your local sales representative for more information.
Related products
Inserts & inner fittings
FiberFlute cushioning
