Packaging rules are tightening around the world. The EU restricts expanded polystyrene (EPS) under Directive (EU) 2019/904, and China’s first compulsory national standard on restricting excessive express packaging took effect on July 1, 2026, capping ordinary parcels at 2 layers and fragile items at 4, with tape usage quantified. Layer counts are going down, but protection cannot. That is why polyurethane foam-in-place is becoming the material of choice for logistics cushioning.

What the new rules mean for shippers

The rules target oversized cartons, redundant layers and excessive tape. In China, industry regulations also prohibit toxic materials and EPS as void-fill cushioning. The old habit of “wrapping more layers” no longer works — precise, minimal packaging that still protects is the compliant and cost-saving direction.

Why polyurethane foam-in-place replaces multi-layer cushioning

Foam-in-place generates cushioning in the shape of the product: A/B chemicals mix and expand instantly, conforming 360° around the item, so one foam layer replaces the old stack of carton + pre-cut foam + bubble wrap. Field data from CosMolar customers: one package takes 1-2 minutes instead of 3-10 minutes; the damage rate drops below 0.5%; total packaging cost falls 30-50%. Density is adjustable at 6/17/23 kg/m³ — high density for heavy parts, low density for light ones. Cushioning outperforms PE foam sheets, and the foam is recyclable, fitting green packaging trends.

Export orders: three compliance documents to ask for

When sourcing polyurethane foam packaging materials, check three documents first:

1. RoHS test report: confirms restricted hazardous substances are absent (CosMolar’s core consumables passed EU RoHS testing — CTI report dated 2025.09, available in Chinese and English);
2. Transport identification certificates: issued separately for road, sea and air, confirming non-dangerous goods status (CosMolar’s polyether polyol, MDI and flushing solvent are certified by Shanghai Institute of Chemical Industry Testing, SICIT);
3. MSDS (Material Safety Data Sheet): Chinese and English versions available to share with customers and carriers.

With these three documents, customs clearance and customer audits run smoothly.

What this means for buyers

New rules do not mean “pack less”; they mean “pack precisely”. Instead of adding layers, match the cushioning to the product: hand-tear bags for small volumes, foaming machines for high volume, and the right foam density for the load. When in doubt, run free sample tests with the manufacturer and decide with real data.

CosMolar is the foam-in-place packaging source factory, headquartered in Shenzhen with production in Foshan, focused on polyurethane foam materials and foaming equipment, with complete environmental compliance documentation for export. Free sample testing and a 1-year machine warranty are available. Website: https://www.cosmolar.com/