Method for packaging and transporting compressed foam sponges at up to 20 times higher density than normal without losing shape or size after returning the sponge to its original form

A method for making, compressing, packaging, transporting and unpackaging an open cell foam, then returning the foam to an original uncompressed size and shape, the method comprising the following steps:

• making an open cell foam by reacting a mixture of polymer ingredients and a blowing agent including a plasticizer to make a foam with density between 5 and 60 kg/m3;
• cutting the foam into product units thereby forming a foam product;
• adding water to the foam product prior to packaging, wherein the water is 30% or less by weight of water to foam weight, wherein the water includes an antimicrobial between 0.1 and 0.3% by weight of antimicrobial ingredient to foam weight;
• inserting the foam product and supporting inserts into a packaging comprising a sealable plastic bag or sleeve;
• compressing the foam product while inside the packaging, wherein the compressing includes compressing both the foam product and the packaging mechanically between two plates, while under vacuum, or both, wherein the compressing is carried out to achieve a foam density between 5 and 20 times the original uncompressed density of the foam product, wherein the supporting inserts are made of cardboard, paper, plastic, film, or metal to cover parts or all of the foam surfaces inside the compressed package;
• sealing the foam product and the supporting inserts within the sealable plastic bag or sleeve to form a package of the compressed foam and the supporting inserts;
• transporting the package;
• unpackaging the foam product and releasing it from its compressed state;
• subjecting the foam product to water and/or heat either by rinsing the foam in household water between 25° C. to 50° C. or by using a hot air blower at temperatures above 25° C. such that the foam product returns to the original uncompressed size and shape without losing any of its resilience, shape or form within 5 to 60 seconds.