In the protective packaging industry, weight has always been the adversary. For decades, the rule was simple. If you wanted maximum protection, you had to accept maximum weight. Thick walls, heavy ribs, and dense materials were the only way to guarantee that sensitive equipment would survive the rigours of transit.
That rule no longer applies.
Welcome to the revolution. Welcome to the Peli Air range, available now from PottertonPacs.
As the leading UK distributor for Peli products, PottertonPacs is proud to supply this game changing innovation to British industry. Peli Air cases are the first in a series of remarkable innovations engineered by Peli, the pioneers of protective cases. For over 40 years, Peli has designed and crafted the most influential protective cases in the world. With the launch of the Peli Air line, they have redefined the future of protection with a remarkable union of light and tough.
These cases are designed to be up to 40% lighter than standard Peli cases. Yet they withstand the exact same crushing loads, the same extreme temperatures, and the same rough handling. For our B2B clients in media, aerospace, field service, and defence, the Peli Air range represents a significant operational advantage. It allows you to reduce freight costs, meet strict airline baggage limits, and protect the health of your workforce by reducing the load they carry.
The Science of Light: HPX² Polymer Technology
How do you cut the weight of a case by nearly half without sacrificing the legendary Peli durability? You change the chemistry.
The Peli engineering team challenged themselves to defy the laws of physics. They knew that simply making the walls thinner using standard materials would result in a weaker case. To solve this, they developed a proprietary formula known as HPX² polymer.
This next generation resin is unlike anything else on the market. It is engineered to rebound from stress. When an impact occurs, the material flexes to absorb the energy and then instantly returns to its original shape. This unique elasticity allowed Peli engineers to design a case with a honeycomb structural geometry that is actually stronger than solid polymer in many applications.
The result is a case that feels incredibly light in the hand but acts like a tank under pressure. At PottertonPacs, we have seen these cases dropped on concrete, submerged in water, and stacked under heavy pallets. They perform flawlessly. The Peli Air is not just a lighter case. It is a smarter case.
Reducing Logistics Costs and Carbon Footprint
For a procurement manager or logistics director, weight is money.
Every kilogram you ship costs your business capital. Whether you are paying for excess baggage on a commercial flight, calculating fuel burn for a fleet of service vans, or paying shipping rates for international freight, heavy packaging eats into your margin.
By switching your fleet to Peli Air Cases UK, you can achieve immediate savings.
• Airline Travel: Many Peli Air models are designed specifically to maximise the usable volume within airline weight restrictions. The weight you save on the case can be used for extra batteries, lenses, or tools.
• Freight Efficiency: For bulk shipments, a 40% weight reduction across hundreds of units translates to tonnes of saved weight. This can significantly lower shipping tiers and reduce your company carbon footprint.
• Health and Safety: Manual handling injuries are a major concern for UK employers. By providing your engineers and technicians with lightweight Peli Air cases, you reduce the physical strain of lifting equipment in and out of vehicles, lowering the risk of back injury and fatigue.
The Design Language of Peli Air
The Peli Air range is not just a material update. It is a total design overhaul. While maintaining the classic DNA of the Peli brand, the Air series introduces a modern, sleek aesthetic that appeals to professional users.
Conic Curve Lid Shape: The lid of a Peli Air case features a distinctive conic curve shape. This adds stiffness to the lid, preventing it from bowing under heavy loads, while also giving the case a sharp, contemporary look.
Proven Tough Latches: The cases utilise the classic double throw latches that users love. They provide enormous closing force to compress the O ring seal but are easy to open when you need access.
Card Holder: Every Peli Air case comes with a polycarbonate card holder. This can be placed on the front or side of the case, making it easy to identify specific kits or add shipping labels without using sticky tape that leaves residue.
Colour Choices: Unlike the standard range which is often limited to black, the Peli Air range is available in four standard colours: Black, Yellow, Orange, and Silver. For B2B clients, this allows for instant visual categorisation. You can put your lighting kit in yellow cases and your audio kit in black cases, streamlining your workflow on busy sets.
Form Factors for Every Application
The Peli Air range has expanded rapidly to cover almost every possible requirement. At PottertonPacs, we stock the full variety of shapes and sizes.
The Carry On Revolution: Peli Air 1535
The undisputed star of the range is the Peli Air 1535. This case was designed with one specific goal: to be the ultimate maximum carry on size for air travel. It fits perfectly into the overhead bins of most major airlines. For photographers and travelling engineers, the 1535 is the holy grail. It offers the maximum possible internal space while weighing just a few kilograms. It features quiet rolling stainless steel bearing wheels and a retractable extension handle, making navigation through Heathrow or Gatwick effortless.
Deep Cases for Drones and Cinema
Equipment is changing. Drones are taller. Cinema cameras are boxier. To accommodate this, Peli introduced the Deep series within the Air range. Models like the Peli Air 1557, 1607, and 1637 offer significant depth. This allows you to store equipment vertically rather than horizontally. You can stack layers of foam to maximise density, fitting more gear into a smaller footprint.
Long Cases for Precision Tools
For surveyors, hunters, and architects, the Peli Air Long cases are essential. Models like the Peli Air 1745 are designed to hold tripods, lighting stands, firearms, or architectural rolls. They offer the length you need with the rigidity required to prevent long items from bending or warping during transport.
Interior Options: Beyond Empty Boxes
A Peli Air case from PottertonPacs is a blank canvas. To truly protect your assets, you need the right interior. We offer several configuration options to suit your needs.
1. No Foam (Empty)
For clients who want to use their own padding or simply need a waterproof container for cables and robust items, buying the case empty is the most cost effective option.
2. Pick N Pluck Foam
The classic DIY solution. This pre scored foam allows you to pluck out small cubes to create a cavity shaped like your equipment. It is quick, easy, and requires no tools. It is ideal for one off cases or rapid deployment.
3. Padded Dividers
For users whose loadout changes daily, padded dividers are the best choice. These velcro compatible dividers allow you to reconfigure the interior compartments in seconds. If you are a photographer carrying a telephoto lens today and a flash kit tomorrow, dividers give you the flexibility you need.
4. TrekPak System
TrekPak is a premium divider system exclusive to Peli. It uses rigid, waterproof panels and steel pins to create a highly organised, space efficient interior. It is incredibly durable and allows you to fit more gear into the case than traditional foam or dividers because the walls are much thinner.
The PottertonPacs Advantage: Custom Foam Engineering
For our B2B customers ordering in bulk, the most powerful option is our Custom Foam Service.
At PottertonPacs, we are experts in protective packaging design. We do not just sell cases; we engineer solutions. When you place a volume order for Peli Air cases, we can design and manufacture bespoke foam inserts tailored specifically to your equipment.
Using advanced CNC routing and water jet cutting technology, we create inserts that hold your items with millimetre precision.
• Professional Presentation: A custom foam insert looks incredibly high end. When your sales team opens a case in front of a client, the neat, organised layout speaks volumes about your company professionalism.
• Asset Management: We can use dual colour foam (shadow foaming) to provide instant visual inventory. A bright colour layer sits beneath a dark top layer. If a tool or component is missing, the bright colour is revealed. This is essential for aviation maintenance and medical environments where ensuring every tool is accounted for is a safety critical requirement.
• Optimised Protection: We select the correct foam density based on the weight of your object. Heavy items need denser foam to prevent them from bottoming out during a drop, while delicate optics need softer foam to dampen vibration. Our engineering team handles these calculations for you.
Corporate Branding and Personalisation
Your cases are visible assets. They travel through airports, sit in hotel lobbies, and appear on job sites. They should carry your brand.
PottertonPacs offers comprehensive corporate branding services for the Peli Air range. Because the Peli Air lid is rigid and smooth, it is the perfect surface for high quality screen printing. We can apply your logo, contact details, or “Fragile” warnings directly onto the case.
We also offer high performance vinyl labels and resin domed badges. Branding your cases not only promotes your business but also acts as a powerful theft deterrent. A case clearly marked with “Property of [Your Company]” is much less likely to “walk away” from a shared site than a generic black box.
Industries Trusting Peli Air
The adoption of Peli Air Cases UK wide has been rapid. We supply these cases to a diverse range of sectors:
Film and Broadcast Camera crews are often moving fast and carrying heavy rigs. The Peli Air 1615 is the maximum check in size for most airlines. Media teams use this case to transport lighting heads, monitors, and camera bodies, maximising their baggage allowance without paying overweight fees.
Emergency Services Paramedics and first responders carry heavy medical kits. Every gram of weight saved on the case is energy saved for the medic. The hygiene properties of the smooth polymer also make Peli Air cases easy to wipe down and decontaminate.
Defence and Security While the classic Protector case remains a military staple, the Peli Air is seeing increased adoption for specialist units, drone operators, and communications teams who need to be agile and mobile in the field.
Field Service Engineers Technicians who travel to repair wind turbines, servers, or medical scanners need to carry diagnostic tools. Peli Air cases protect these expensive computers and calibrators from rain, dust, and impact while being light enough to carry up stairs or ladders.
Peli Air vs Peli Protector vs Peli Storm
Our clients often ask us to compare the ranges. Here is a quick guide to help you choose.
Choose Peli Protector if:
• You need the absolute maximum crush resistance possible.
• Weight is not a concern (e.g., the case will rarely be moved by hand).
• You need a very specific size that is only available in the vast Protector catalogue.
• You prefer the traditional robust aesthetic.
Choose Peli Storm if:
• You prefer the Press and Pull latch mechanism which is quieter and easier to open.
• You are operating in extremely cold environments where the specific Storm resin excels.
Choose Peli Air if:
• You travel by air frequently.
• You carry the case by hand over long distances.
• You want to reduce shipping costs.
• You want a modern, sleek look.
• You need the Deep form factor for stacking gear.
The Peli Guarantee of Excellence
Like all products in the Peli family, the Peli Air range comes with the legendary Lifetime Guarantee. “You break it, we replace it… forever.”
It is that simple. This warranty gives procurement managers total peace of mind. When you invest in a fleet of Peli Air cases from PottertonPacs, you are making a one time investment. You will not need to replace cracked or broken cases next year. These cases are built to last a lifetime. Please note that the guarantee covers the case shell, latches, and handles, but not the foam interior or the contents.
Ready to Lighten the Load?
The era of heavy protective packaging is over. With Peli Air Cases UK, you can have the best of both worlds: the legendary protection you trust, with a lightweight design that transforms your logistics.
At PottertonPacs, we are ready to help you make the switch. We hold extensive stock of the entire Peli Air range at our UK warehouse. Whether you need a single sample to test or a bulk order of five hundred units with custom foam and logo printing, our team is here to deliver.
Do not let heavy cases slow your business down. Upgrade to Peli Air.
Contact the PottertonPacs team today to discuss your project, request a trade quotation, or explore our customisation options.
Frequently Asked Questions about Peli Air
Are Peli Air cases waterproof? Yes. All Peli Air cases feature a polymer O ring seal and a tongue and groove fit. They are watertight and dustproof, typically rated to IP67 standards. They also feature the automatic pressure equalisation valve to prevent vacuum lock.
Are they really as strong as the standard Peli cases? In practical terms, yes. While the wall thickness is lower, the HPX² material is more advanced. They pass the same drop tests, submersion tests, and handle strength tests as the heavier Protector cases. Unless you are planning to drive a tank over them, Peli Air provides all the protection you will ever need.
Can I get Peli Air cases in different colours? Yes. We stock Peli Air cases in Black, Yellow, Orange, and Silver. This is excellent for colour coding your equipment. For very large bespoke orders, we can even discuss custom colour runs.
What is the maximum carry on size? The Peli Air 1535 is designed to meet the maximum carry on dimensions for most major airlines. However, we always recommend checking with your specific airline before travel as regulations can change.
Can PottertonPacs foam fit my specific tools? Absolutely. This is our speciality. We can take your tools, scan them, and design a layout that fits them perfectly into a Peli Air case. We can ensure finger cutouts are included for easy removal and that heavy items are balanced correctly.
