Dynamic Cushioning Performance and Sustainability Implications of Recycled‐Content Expanded Polyethylene Foams

ABSTRACT The transition toward circular materials in protective packaging requires empirical evidence that recycled‐content foams can satisfy stringent shock‐attenuation requirements. This study evaluates the dynamic cushioning performance of expanded polyethylene (EPE) foams formulated with 0%, 30% and 40% recycled content under controlled impact conditions following ASTM D1596. A total of 1100 drop tests were conducted across combinations of density, thickness, static load and drop height representative of distribution hazards in parcel and freight supply chains. Peak transmitted acceleration (G) was measured as the primary performance response variable. Across the configurations evaluated, recycled‐content EPE foams exhibited cushioning performance comparable to virgin materials. Within the tested design space, the 30% recycled‐content formulation was associated with lower mean peak transmitted accelerations and reduced variance relative to virgin foam. However, these differences are configuration‐dependent and should not be interpreted as a universal performance improvement. Multivariate regression analysis identified recycled content as a statistically significant predictor of reduced peak acceleration after controlling for geometry, density, drop height and static load, while confirming that thickness and impact severity remain the dominant determinants of cushioning behaviour. Increasing thickness from 2.5 to 5.1 cm reduced peak acceleration by more than 70 G, underscoring the primary role of geometric design in shock mitigation. Overall, these results demonstrate that moderate recycled‐content levels, particularly 30% within the commercially available formulations tested, can be incorporated into EPE foams without compromising protective performance. The study provides design‐relevant evidence supporting the adoption of recycled polymers in cushioning applications and contributes to sustainability efforts aimed at reducing reliance on virgin plastics in protective packaging systems.