The family run specialist manufacturer of custom-made protective packaging

Protective foam packaging

We are a leading converter of industrial and technical foams. Our manufacturing processes include hot-wire cutting, band-knifing, profiling, contouring, die-cutting, slitting, boring, CNC routing and knifing, heat-welding/gluing/laminating

Image showing a collage of protective foam packaging

Film & theatre

We are a major packaging supplier to the film Industry, television and theatre companies, shop display, exhibition, themed events and other similar industries, supplying a wide range of products and materials to Construction Managers, Sculptors, Special Effects, Prop Makers, Model Makers, Scenic Artists and Designers

Image showing film set lights

Timber products

We manufacture bespoke ply/batten wooden crates and cases, as well as non-standard-size wooden pallets. We are an FSC accredited member of the UK Wood Packaging Material Marking Programme and approved by the Forestry Commission to provide ISPM-15 certified wood packaging

Image showing a collage of wooden crates

Sustainable materials

Our Envirafoam® range of packaging materials offers the choice of a ‘greener’, more sustainable protective packaging solution. These new, cutting-edge materials provide viable alternatives to traditional petrochemical based foam plastics, often without compromising performance

Image showing a forest

Who are Excel Packaging & Insulation?

Excel Packaging was founded by Graham Woolley in January 1994. We are a specialist UK manufacturer and supplier of custom-made protective packaging solutions and thermally insulated boxes. We design and manufacture solutions for a wide range of industries including industrial products, consumer products, presentation/point-of-sale, electronics, IT, medical/pharmaceutical & food (cold chain), construction & civil engineering, heating & ventilation, as well as supplying materials for scenic construction for film, television & theatre.

Our experienced packaging design team have a wide selection of materials and manufacturing processes at their disposal that reduce damage in transit, make your products stand out from the competition and provide a cost-effective and environmentally friendly packaging solution.

We are a leading converter of industrial and technical foams such as expanded polystyrene foam, extruded polystyrene foam, expanded polyethylene foam, flexible polyurethane/polyether foam, Plastazote® foam, expanded polypropylene foam and Fibrease® wood foam.

Excel Packaging’s growth can largely be attributed to our unwavering commitment to continually re-invest, coupled with the desire to provide fantastic customer service to all our customers! 

Image showing a collage of different packaging
Icon showing polystyrene

Expanded polystyrene

Excel supplies expanded polystyrene sheets or pads in a range of different grades/densities, cut to the required length, width, and thickness.  In addition, shaped packaging components can be manufactured using hot-wire cutting and CNC routing techniques.

Icon showing corrugated cartons

Short-run corrugated cartons

We manufacture short-run corrugated boxes, in either regular ‘slotted’ or diecut Fefco styles, together with other corrugated components/fittings, from either single wall, double wall or CA flute board grades, selected to suit the specific requirements of each project.

Icon showing cold boxes

Thermally insulated cold boxes

We stock a comprehensive range of moulded polystyrene (EPS) cold boxes for the transportation of temperature-sensitive goods. EPS cold boxes provide a high-performance, lightweight, water-resistant, hygienic solution for many different cold chain applications, including medical, pharmaceutical and food.

Icon showing honeycomb board

Paper honeycomb board

Paper honeycomb board is a lightweight, 100% recyclable sheet material, available in a wide range of thicknesses and grades. Our in-house design team provides environmentally sustainable, cost-effective protective packaging solutions tailored to your specific needs.

Image showing foam packaging



Envirafoam® WP is a lightweight wood fiber-based foam material made from Nordic wood. The material is fully recyclable in existing paper/board streams and has been designed to replace traditional 'polymer' foams in some packaging solutions. It can also be used as a viable alternative to Polystyrene where thermal insulation is required.

Image showing wooden crates
Image showing polystyrene being heated
Image showing a forest
Image showing shaped packaging
Image showing shaped packaging
Image showing different types of packaging
Image showing the Excel team at work

Quality and service since 1994

Excel Packaging is a designer and manufacturer of custom-made protective packaging and thermally insulated boxes to protect and enhance your products. Our experienced design team has at its disposal a wide range of different materials and manufacturing processes that can be applied to reduce damage in transit, make your products stand out from the competition and provide a cost effective and environmentally conscious packaging solution.

Utilising our many years of experience, we will achieve the best outcome for your project, striving to deliver optimum performance while also considering reusability, recyclability and sustainability, all delivered at a competitive price!

image showing man lifting a foam cooler box isolated on white background.

Moulded polystyrene cold boxes & fabricated cold boxes

Excel packaging is a UK manufacturer, stockist and supplier of moulded polystyrene (EPS) cold boxes and bespoke fabricated cold boxes. Both products provide a lightweight, water resistant, hygienic, and low-cost packaging solution for the transportation of temperature sensitive products. We offer a wide selection of moulded cold boxes available for nationwide delivery within 1-3 days.  

In addition, we can also create custom made fabricated cold boxes available in a range of different insulation materials determined by the thermal performance you require. These fabricated designs can be supplied flat-packed to reduce shipping and storage space costs or can be supplied fully assembled and ready for use. 


  • Excel Packaging are a great company. We have dealt with them for decades because they have consistently given us fantastic customer service. They are up to date on the latest regulations and raw materials. They have a huge range of skills and knowledge in a wide range of special packaging materials and are worth a call. Most recently, they have helped with sustainable foam products.

    Luke Jamieson

    Aylesbury Box Co
  • Since being introduced to Excel Packaging we have found them to be an excellent supplier, communication is excellent and we really appreciate the personal service. All too often now e-mail seems the first point of contact but you tend to lose content in messages. Mark is always keen to visit and fully understands and provides solutions to our requests, backed up with samples and all in a timely manner. Excel are a gem of a company that are too often hard to find these days. Keep up the good work.

    Justin Burrell

    Barton Jones Packaging Ltd

Latest news

Understanding Protective Packaging
Earth day diversity and cultural celebration as diverse global cultures and multi-cultural unity.

Our videos

Custom made packaging
Wooden crates
ISPM 15 accreditation video