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EVA foam resin for midsoles, sandals, mats and foam sheet: VA, melt index and how to order

We source EVA foam grades for compounders and for footwear, sports, mat and packaging foam makers, from one gaylord (about 1,000 to 1,600 lb) to a truckload. Send the grade you run, or its VA content, melt index and foam process, and a polymer chemist reviews it and quotes a match or a qualified equivalent.

Updated October 2026

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The short answer

Typical VA windows for crosslinked EVA foam: footwear midsoles often about 18–22% VA, with some grades up to about 28%; packaging foam can start near 4–6% VA. Footwear foam grades run at a melt index of about 1.5–4 g/10 min (190°C / 374°F, 2.16 kg), and packaging foam often blends low-VA EVA with LDPE. The foam formula (peroxide, blowing agent, activator, filler and any POE, OBC or rubber) is tuned to the exact base grade, so match VA and melt index first, then trial before you switch.

VA and melt index by foam product

Pick the row for what you make, then compare your current grade with the window. Every melt index here is at 190°C / 374°F and 2.16 kg (ASTM D1238). VA content is measured by the producer’s own method, often FTIR (ASTM D5594 is the ASTM method). For how EVA lines up across all uses, see EVA by vinyl acetate content.

Product	Typical VA	Typical MI (190°C / 374°F, 2.16 kg)	What matters most
Running and athletic midsoles (compression-molded or injection foam)	Often about 18–22%; some grades up to about 28%	About 1.5–4 g/10 min	Density, hardness, compression set, rebound and heat shrinkage. Often blended with POE or OBC. Higher VA gives a softer, more rubbery foam.
Flip-flops, sandals and slippers (slab sheet or injection)	About 15–22%	About 1.5–3 g/10 min	Cost, filler loading, hardness and skin finish. Rubber is often added for grip and wear on one-piece soles.
Yoga, gym, play and puzzle mats; craft foam sheet and toys	Often the same 18–20% VA foam grades, sometimes blended with LDPE	About 1.5–3 g/10 min	Density and feel, cell size, color and odor. Brand and toy rules on formamide and other residues apply. See the blowing agent notes below.
Packaging, protective and cushioning foam (crosslinked PE/EVA)	Low VA, starting near 4–6%, often blended with LDPE	About 0.5–2 g/10 min	Density and compression strength. Several low-VA film grades list foam as a use, so a film grade can be the right base resin here. See EVA film grades.
Automotive and industrial foam (gaskets, seals, pads, underlay)	Mid-VA foam grades or PE/EVA blends, set by the formula	Ask: set by the foam formula and process	The OEM’s odor, fogging and flammability tests (for example FMVSS 302 for interior materials), compression set at temperature and long-term recovery.
Soft, high-filler or high-rebound compounds	About 26–28%	About 2–4 g/10 min	Filler acceptance, softness and adhesion. High-VA pellets block more easily in warm storage. For 28% VA grades across all uses, see 28% VA EVA.

Windows are drawn from published producer foam-grade data sheets (Korean, U.S., Saudi and Taiwanese producers) and are typical, not limits. The foam formula and process decide the final properties, so confirm against the data sheet for the grade you run.

Crosslinking and blowing: peroxide, ADC and physical foaming

Most EVA foam is crosslinked and chemically blown. A peroxide links the chains so the melt holds gas without collapsing, and a blowing agent breaks down in the hot mold to make the cells. Both are compounded into the EVA cool, on a kneader and two-roll mill or a cool injection barrel, so they do not react early. One producer’s foam-grade sheets list kneader temperatures of about 70–110°C / 158–230°F, lower for higher-VA grades.

Peroxide crosslinker. Dicumyl peroxide (DCP) is the most common. More peroxide gives a tighter network, higher hardness and lower compression set, but too much limits expansion. DCP leaves breakdown products such as acetophenone and 2-phenyl-2-propanol, which some brand restricted substance lists track in EVA foam.
Chemical blowing agent. Azodicarbonamide (ADC, also called AC or ADCA) is the most widely used. On its own it breaks down too hot for EVA, so zinc oxide or zinc stearate activators bring it down into the molding range. The ratio of blowing agent to peroxide sets density and cell structure.
ADC rules to check. The EU has banned ADC as a blowing agent in plastic food-contact materials since 2005, and it is on the EU REACH Candidate List of substances of very high concern as a respiratory sensitizer. Formamide, which has been found in some EVA foam mats and is linked to ADC blowing systems, is limited in EU foam toy materials, and recent versions of the AFIRM restricted substances list add a formamide limit for yoga, play and baby mats and list acetophenone azine, which can form in foam blown with ADC and crosslinked with DCP. Rules differ by market and change. Check the current rules for every market your product ships to.
Other blowing agents. OBSH, sodium bicarbonate and citric acid systems, and expandable microspheres are used where ADC is restricted or a finer, whiter foam is wanted. Each changes the formula, so treat a switch as a new qualification.
Physical foaming. Supercritical nitrogen or carbon dioxide can foam EVA and its blends without a chemical blowing agent, and is used for some light, high-rebound midsoles. It needs dedicated equipment, and the base resin still has to suit the process. Ask us before assuming a chemical-foam grade will work.

Injection-molded foam vs. compression-molded slab foam

The process changes which grade runs best and what you need on the RFQ. Many plants run more than one.

Process	How it works	Typical products	Watch for
Slab or sheet foam (open press)	Compound is milled to sheet, cured and blown in a heated press, then released so the slab expands. Slabs are skived and die-cut.	Flip-flops, insoles, mats, craft sheet, blanks for compression molding	Trim scrap, skin removal and slab-to-slab density. Crosslinked trim cannot be remelted like thermoplastic regrind.
Compression-molded foam (often called phylon or CMEVA)	A foam blank is pressed again in a heated mold, then cooled in the mold to set the final shape and skin.	Midsoles with sharp detail and a tight skin	Two heat cycles, so cycle time and energy are higher. Shrinkage and hardness depend on how far the blank is compressed.
Injection-molded foam (IP)	Compound pellets or strip are fed to a cool barrel, about 80–110°C / 176–230°F, and injected into a mold at about 160–190°C / 320–374°F. The part cures and expands as the mold opens. Cycles often run several minutes.	One-piece clogs, sandals, midsoles	Barrel temperature: too hot and the peroxide and blowing agent react early. Expansion ratio, shrinkage after demolding and mold-to-mold consistency.

Temperatures are typical published ranges from patents and process literature. Your compound supplier’s sheet and your own trials set the real window.

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Blending EVA with POE, olefin block copolymers and rubber

POE (polyolefin elastomers). Ethylene-octene or ethylene-butene POE is added for softness, rebound and lighter foam. It changes how peroxide cures the blend, so the formula often needs adjusting. See metallocene PE, plastomers and POE.
Olefin block copolymers (OBC). Producers promote OBC in midsoles for better recovery and compression set, including at warm temperatures. Test your own blend for compression set and shrinkage before you commit.
Rubber. Natural rubber, BR, SBR or EPDM is blended in for grip, abrasion resistance and a rubbery feel, mostly in one-piece soles and outsole-type foams.
LDPE. Blended in for stiffness and lower cost, mostly in packaging foam and some mats.
Match the whole blend. If you change the EVA, keep the POE, OBC or rubber the same and change one thing at a time. A blend that ran on one EVA can foam to a different density on another with the same VA and melt index.

What sets density, hardness, compression set, rebound and shrinkage

Brands and foam makers specify finished foam, not resin. Footwear foams described in published patents run about 0.1–0.2 g/cm³ and about Asker C 40–60. Mats, slippers and packaging foam cover a wider range. Agree the test method with your customer first, because two labs on different methods will not agree.

Property	How it is often measured	What moves it
Density	Specific gravity by weighing in air and water, or ASTM D3575 Suffix W for olefin foams	Blowing agent level and activator, peroxide level, mold fill and expansion ratio. A melt index change in the base EVA shifts density at the same formula.
Hardness	Asker C durometer for most footwear foam; Shore A or Shore C (ASTM D2240) for denser foams and solids	Density first, then VA content (higher VA is softer), crosslink level, filler and POE or OBC share.
Compression set	Footwear tests often compress samples to 50% at 50°C / 122°F for about 6 hours, then measure recovery; ASTM D395 for solids	Crosslink density, base resin and blend partner. OBC and a fuller cure help; undercure and high soft-polymer content hurt.
Rebound (resilience)	Ball rebound (ASTM D3574 Test H, written for urethane foam) or the brand’s own rebound method	Polymer choice and crosslink level. POE, OBC and physical foaming are common routes to higher rebound.
Shrinkage	Measured after a set time in a warm oven, by the brand’s or foam maker’s method	Foam shrinks after molding as gas diffuses out and stresses relax, and more in heat. A stabilizing heat cycle after molding and a formula matched to the use temperature reduce it.

Patent values and test conditions are examples, not specifications. Use your customer’s method and limits.

Producer families and matching a foam grade

EVA foam grades come from producers in North America, Latin America, Europe, Asia and the Middle East. Examples of trade names you may see on a formula sheet include Elvax (Dow), Ateva (Celanese), Elevate (Westlake), ExxonMobil EVA (grades formerly sold as Escorene Ultra) and Evatane (SK Functional Polymer), plus many Asian producers that use numeric grade codes. We name these only so you can recognize them; the names belong to their owners. We source by spec and do not imply we sell any brand.

Same VA and MI from another producer. The closest swap, but not a drop-in. Foam density, cure and shrinkage still shift, so run a trial batch.
Tubular vs. autoclave. EVA is made in both reactor types, and many producers state which on the data sheet. The molecular structure differs, which can change melt strength and how the foam expands. Match the reactor type when you can.
Additives. Some foam grades carry an antioxidant and some carry none. Antioxidant can slow peroxide cure, so a change here can shift hardness and compression set.
Generic prime. First-quality resin sold without the producer’s grade name. It can work well for slab and mat foam where you test every lot. Ask who made it and get a lot COA.

Packaging, storage and pellet blocking

Package	Typical net weight	Notes
Bag	55 lb (25 kg), often about 40–55 bags per pallet	The most common package for EVA foam grades, and it suits batch weighing at the kneader. Much imported EVA arrives this way.
Gaylord (box with liner)	About 1,000–1,600 lb	Common for domestic resin and larger compounding runs. Ask for an intact liner.
Bulk truck or railcar	About 40,000–50,000 lb by truck; about 180,000–210,000 lb by railcar	For large foam or compounding plants with silos. High-VA pellets can bridge in silos and hoppers if they get warm.

Higher VA grades soften at lower temperatures. One producer recommends storing EVA at about 10–25°C / 50–77°F and not above 35°C / 95°F, out of direct sun, using pallets first in, first out and avoiding double stacking. Many high-VA grades are dusted with an anti-blocking agent. Say if dusting is a problem for your compound.

What moves EVA foam resin prices

We do not post prices. Every quote is for a specific grade, quantity, package and ship-to city. For how EVA is priced across grades, see EVA price per pound. These are the drivers we watch.

Feedstocks. EVA is made from ethylene and vinyl acetate monomer (VAM). VAM is made from ethylene and acetic acid, so both chains matter, and higher VA grades carry more VAM.
Competing demand for high-VA capacity. The same reactors make 28–33% VA grades for solar panel encapsulant film and hot-melt adhesives. When solar demand surges, foam grades in the upper VA range can tighten too. See 28% VA EVA.
Footwear cycles. Most of the world’s EVA footwear foam is made in Asia, so footwear demand there moves Asian EVA prices and the availability of imported foam grades.
Imports, freight and trade rules. Many foam grades sold in North America are imported. Ocean freight, port timing, exchange rates and any duties change the delivered price.
Order size and package. A truckload costs less per pound than single gaylords, and 25 kg bags cost more to pack and handle. See how resin is priced and the resin market notes.

What to put on the RFQ

VA content, in percent, with the tolerance you accept and the method if your customer names one.
Melt index at 190°C / 374°F and 2.16 kg (ASTM D1238), nominal and range.
Process. Slab, compression-molded or injection foam, and whether you compound in-house or buy compound.
Reactor type and additives. Tubular or autoclave if you know it, antioxidant or none, and whether dusting is acceptable.
The rest of the blend. POE, OBC, rubber or LDPE and their share, so we can flag what a resin change might do.
Restricted substances. Your brand’s RSL, and any limits on formamide, DCP residues or other substances that apply to the finished foam.
Package and storage. 25 kg bags, gaylords or bulk, and how warm your warehouse gets in summer.
Quantity and timing. This order, yearly use, release size and the date you need resin on your floor. Send your ship-to city.
COA values to check. VA content and melt index on every lot. Every prime lot from our suppliers ships with a COA. Keep a retain from each lot.

Common questions

What VA content is best for EVA foam midsoles?

Typical windows: footwear midsoles often about 18–22% VA, with some grades up to about 28%; packaging foam can start near 4–6% VA. Midsole grades run at a melt index of about 1.5–4 g/10 min (190°C / 374°F, 2.16 kg). Higher VA gives a softer, more rubbery foam, and many midsoles also blend in POE or OBC. Match the grade your formula was built on, then trial any change.

Can I swap one EVA foam grade for another with the same VA and melt index?

Often, but not as a drop-in. Reactor type, additives and molecular structure differ between producers, and they can shift cure, density and shrinkage at the same formula. Run a trial batch and check density, hardness, compression set and shrinkage before you change production.

Is azodicarbonamide (ADC) banned in EVA foam?

Not everywhere, but it is restricted in some uses and markets. The EU bans it as a blowing agent in plastic food-contact materials and lists it as a substance of very high concern. Formamide, a breakdown product, is limited in EU foam toys and in some brand rules for mats. Check the current rules for each market you sell into.

What is the difference between injection EVA foam and phylon?

Injection foam (IP) is molded and expanded in one step from a compound. Phylon, or compression-molded EVA, starts as a foam blank that is pressed again in a heated mold and cooled in shape. Phylon gives sharper detail and a tighter skin but takes two heat cycles.

Why does my EVA foam shrink after molding?

Gas diffuses out of the cells and molded-in stresses relax, and heat speeds both. Undercure, a soft blend and skipping a stabilizing heat cycle make it worse. A base resin change can also shift shrinkage, so check it whenever you change grade or supplier.

What is the minimum order for EVA foam resin?

One gaylord, about 1,000 to 1,600 lb, or the equivalent in 55 lb (25 kg) bags. Larger plants can buy by the truckload. To qualify a production grade, ask about a sample of about 50 lb, available upon credit approval.

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EVA foam resin, matched by VA, melt index and process

Send the grade on your formula sheet, or its VA content, melt index and foam process, and a polymer chemist matches it or a qualified equivalent and quotes it. We aim to send your quote within one to three business days.